CN117841356A - Laminated modeling apparatus, method for manufacturing three-dimensional modeling object, and teaching method - Google Patents
Laminated modeling apparatus, method for manufacturing three-dimensional modeling object, and teaching method Download PDFInfo
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- CN117841356A CN117841356A CN202311112359.3A CN202311112359A CN117841356A CN 117841356 A CN117841356 A CN 117841356A CN 202311112359 A CN202311112359 A CN 202311112359A CN 117841356 A CN117841356 A CN 117841356A
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Abstract
The invention provides an unmanned laminated modeling device capable of removing modeling objects by removing surplus materials on a modeling workbench more appropriately, a manufacturing method of three-dimensional modeling objects and a teaching method. The laminated molding apparatus of the present invention comprises: a modeling workbench, a chamber, a material layer forming device, a chuck device, a material recycling device, a conveying robot, a mobile robot and a control device. The chuck device detachably fixes the base plate on the modeling workbench, the material recovery device comprises a suction nozzle, the mobile robot can move the suction nozzle, the control device alternately and repeatedly performs the lifting of the modeling workbench by a prescribed lifting amount and the suction of the residual material powder while controlling the mobile robot to move the suction nozzle according to teaching data, and the teaching data comprises the movement path and the gesture of the suction nozzle corresponding to the shape of the modeling object and the height of the modeling workbench.
Description
Technical Field
The present invention relates to a laminated molding apparatus, a method for manufacturing a three-dimensional molded object, and a teaching method.
Background
Various methods are known for lamination molding of three-dimensional molded articles. For example, a laminated molding apparatus that performs fusion bonding of powder beds is configured such that a base plate is disposed in a molding region on a molding table disposed in a chamber, material powder is supplied to the molding region to form a material layer, and a laser beam or an electron beam is irradiated to a predetermined position of the material layer to sinter or fuse the material powder, thereby forming a solidified layer. By repeating the formation of the material layer and the cured layer, the cured layer is laminated on the base plate, and cutting processing by a cutting mechanism is performed during or after molding as necessary, whereby a desired three-dimensional molded article is produced.
In the lamination molding using material powder such as powder bed fusion bonding, not all of the material powder supplied to the molding region is solidified. After molding, uncured material powder remains on or around the molded article, base plate, molding table, and so the remaining material needs to be removed when the molded article is removed from the chamber.
As disclosed in patent document 1, it is known to provide a suction nozzle for sucking and removing surplus material in a lamination molding apparatus. Before removing the molding, the operator operates the suction nozzle to suck the surplus material, thereby removing the surplus material. In such a stack molding apparatus, there is a need to automatically take out a molded article from a chamber after molding. For example, in the case of performing secondary processing on a molded article, it is desirable to take out the molded article from the stack molding apparatus and automatically perform a series of steps of feeding the taken-out molded article to the secondary processing apparatus. When the molded object is automatically taken out of the chamber, the remaining material after molding needs to be automatically removed. Patent document 2 discloses a structure in which residual material remaining after molding is automatically removed by a suction nozzle.
[ Prior Art literature ]
[ patent literature ]
[ patent document 1] Japanese patent publication No. 6132962
[ patent document 2] Japanese patent laid-open No. 2002-205339
Disclosure of Invention
[ problem to be solved by the invention ]
In a conventional laminated molding apparatus that automatically sucks and removes excess material as disclosed in patent document 2, it is often impossible to sufficiently and completely remove excess material remaining on the bottom plate, molding table, and the periphery of the molding plate, including excess material that has entered the recesses or grooves formed in the molded article. When surplus material remains on the molding table, the high-precision positioning and reuse of the material powder when the base plate or tray to be replaced in the next molding is set on the molding table are adversely affected, and therefore, the molded article cannot be taken out without removing the surplus material by a human hand, which hinders the automation in taking out and carrying the molded article.
The present invention has been made in view of the above circumstances, and an object thereof is to provide a laminated molding apparatus, a three-dimensional molded article manufacturing method, and a teaching method capable of achieving unmanned removal of a molded article by more appropriately removing surplus material on a molding table.
[ means of solving the problems ]
According to the present invention, the following invention is provided.
[1] A stack molding apparatus comprising: in the laminated molding apparatus, the molding table is configured to be movable up and down by a table driving mechanism, the chamber covers a molding area which is an area where a molded object is formed provided on the molding table, the material layer forming apparatus supplies a material powder to a base plate placed on the molding area to form a material layer, the chuck apparatus is disposed on the molding table and is configured to be capable of removably and fixedly holding the base plate in the molding area, the material recovery apparatus includes a suction nozzle capable of sucking the remaining material powder on the molding table, the transfer robot is configured to be capable of taking out the base plate and the molded object molded on the base plate from the chamber, the moving robot is configured to be capable of moving the suction nozzle, and the control apparatus alternately repeatedly controls the table driving mechanism to cause the suction nozzle to perform suction in accordance with the amount of the molded object and the remaining material in accordance with the movement path of the teaching table, and the suction nozzle to perform suction in accordance with the data of the remaining teaching of the molding table.
[2] The laminate molding apparatus according to item [1], wherein the laminate molding apparatus comprises an imaging device configured to be able to acquire an image of an area including at least the base plate and the molded object, and the control device determines whether or not the material powder remains using the image acquired by the imaging device.
[3] The laminate molding apparatus according to [1] or [2], comprising a detecting means capable of detecting a ratio of the material powder in the sucked object sucked by the suction nozzle, wherein the control means determines whether or not the material powder remains based on the ratio of the material powder.
[4] The laminate molding apparatus according to [3], wherein the detecting member is a flow sensor.
[5] The laminate molding apparatus according to any one of [1] to [4], comprising: a powder holding wall surrounding the modeling table and configured to hold the material powder on the modeling table; and a material recovery tank configured to store the remaining material powder discharged to the outside of the powder holding wall, wherein the material recovery device includes a recovery mode and a suction mode as operation modes, wherein the control device is configured to switch the operation modes, and wherein the material recovery device is configured to: in the recovery mode, the material powder in the material recovery tank is recovered, and the material powder is supplied to the material layer forming apparatus after removing the impurities, and in the suction mode, the suction nozzle is moved by the moving robot, the remaining material powder on the modeling table is sucked by the suction nozzle, and the impurities are removed from the material powder.
[6] The laminated molding apparatus as claimed in any one of [1] to [5], wherein a side surface of the chuck device is covered with a chuck cover including an outer cover covering at least a part of a side surface of the inner cover and an inner cover covering the side surface of the chuck device.
[7] The laminate molding apparatus according to any one of [1] to [6], wherein the chuck device fixes the base plate via a mounting plate.
[8] The laminate molding apparatus according to any one of [1] to [7], wherein the suction nozzle includes a suction portion on a tip end side, the suction portion having a cylindrical shape in which an end face on the tip end side is cut off with an inclined face, and an opening portion is provided on the inclined face.
[9] The stack molding apparatus according to any one of [1] to [8], wherein the transfer robot is configured to be capable of transferring the base plate into the chamber.
[10] The stack molding apparatus according to any one of [1] to [9], wherein the transfer robot is configured to invert the molded object after the molded object is taken out of the chamber.
[11] A manufacturing method is a manufacturing method of a three-dimensional modeling object, comprising: in the placing step, a base plate is detachably fixed by a chuck device arranged on a modeling table, the base plate is placed on a modeling area which is an area provided on the modeling table and in which a modeling object is formed, in the solidified layer forming step, a material layer forming step of forming a material layer by supplying a material powder onto the base plate, and a solidifying step of forming a solidified layer by irradiating a predetermined irradiation area of the material layer with a laser beam or an electron beam are repeatedly performed, whereby the solidified layer is laminated, in the pumping step, a step of raising the modeling table by a predetermined raising amount by a table driving mechanism and a step of pumping the remaining material powder while moving a pumping nozzle by a moving robot are alternately performed, and in the taking out step, the base plate and the modeling object molded on the base plate are taken out from a chamber covering the modeling area by a carrying robot, the data including a teaching path corresponding to a shape of the modeling table and a height of the modeling object.
[12] A teaching method for acquiring teaching data for use in sucking surplus material powder generated in a laminated molding of a three-dimensional molded object with a suction nozzle, the teaching method comprising: a mounting step of detachably fixing a base plate by a chuck device disposed on a modeling table, a modeling area which is an area for forming a modeling object provided on the modeling table, a modeling step of repeating a material layer forming step of forming a material layer by supplying a material powder to the base plate, and a curing step of forming a cured layer by irradiating a predetermined irradiation area of the material layer, thereby laminating the cured layer to model a three-dimensional modeling object, and a recording step of manually operating a moving robot to move the suction nozzle, and recording position coordinates and posture of the suction nozzle, wherein the recording step and the raising step are repeated, and the recording step and the raising step are repeated, thereby obtaining teaching data including the suction nozzle movement path corresponding to the shape of the modeling object and the height of the modeling table.
[ Effect of the invention ]
In the laminate molding apparatus of the present invention, a suction nozzle movable by a moving robot is provided, and the suction nozzle is moved in accordance with teaching data while gradually raising a molding table to suck and remove surplus material. The teaching data includes an appropriate movement path and posture of the suction nozzle according to the shape of the molded object and the height of the molding table, so that the surplus material on the molding table can be removed more reliably and efficiently. At this time, since the removal of the surplus material by the suction nozzle is automatically performed, the removal of the molded article can be made unmanned.
Drawings
Fig. 1 is a schematic configuration diagram of a stack molding apparatus 100 according to an embodiment of the present invention.
Fig. 2 is a perspective view of the material layer forming apparatus 2 of the stack molding apparatus 100.
Fig. 3 is a perspective view from above of the applicator head 22 of the material layer forming apparatus 2.
Fig. 4 is a perspective view from below of the applicator head 22 of the material layer forming apparatus 2.
Fig. 5 is a perspective view showing a state in which the bottom plate 83 is fixed to the chuck device 5.
Fig. 6 is a cross-sectional view of line A-A of fig. 5.
Fig. 7 is a perspective view showing a state in which the tray 85, the positioning plate 86, and the shaft 87 are disassembled.
Fig. 8 is a perspective view showing a state in which the chuck cover 53 is detached from the chuck device 5.
Fig. 9a and 9b are diagrams showing the tip of the suction portion 79a of the suction nozzle 79. Fig. 9a is a front view, and fig. 9b is a right side view.
Fig. 10 is a diagram for explaining a suction form of the surplus material layer 81a by the suction nozzle 79.
Fig. 11 is a block diagram of the control device 9 of the stack molding apparatus 100.
Fig. 12 is a flowchart of a method of manufacturing a three-dimensional shaped object W using the stack molding apparatus 100.
Fig. 13 is a flowchart of a teaching method for acquiring teaching data.
Fig. 14 is a diagram for explaining a method of manufacturing a three-dimensional molded article W using the lamination molding apparatus 100.
Fig. 15 is a diagram for explaining a cured layer forming process.
Fig. 16 is a diagram for explaining the suction process.
[ description of symbols ]
1: chamber chamber
1a: window
2: material layer forming apparatus
3: irradiation device
4: modeling workbench
5: chuck device
6: conveying robot
7: material recovery device
8: mobile robot
8a: mechanical arm
8b: mechanical arm
8c: torque sensor
9: control device
10: material supply unit
11: material groove
12: main pipeline
13: intermediate pipeline
13a: intermediate pipe outlet
14: shutter device
17: pollution prevention device
17a: frame body
17b: diffusion member
18: image pickup apparatus
21: base seat
22: coating machine head
22a: material containing part
22b: material supply port
22c: material discharge port
22fb: blade
22rb: blade
23: driving device for coating machine head
41: workbench driving mechanism
42: powder holding wall
51: chuck base
52: clamping unit
52a: first convex part
52b: second convex part
52c: abutment recess
52d: ball bearing
52e: insertion hole
53: chuck cover
54: outer cover
54a: outside coating part
54b: upper surface portion
55: inner side cover
55a: inner coating part
55b: flange part
70: material recycling bin
70a: powder discharge part
70b: powder discharge part
70c: chute guide
70d: chute guide
70e: chute groove
71: material recovery conveying device
71a: exhaust port
71b: suction port
72: switching valve
73: impurity removing device
74: suction device
75: switching valve
76: material supply barrel
77: material drying device
78: material supply conveying device
78a: exhaust port
79: suction nozzle
79a: suction part
79b: an opening part
81: material layer
81a: residual material layer
82: cured layer
83: bottom plate
84: mounting plate
85: tray for holding food
86: positioning plate
86a: a first opening part
86b: a second opening part
86c: supporting leg
86d: mounting shaft
87: shaft
87a: clamping bolt
87b: locking part
87c: concave part
90a: CAD apparatus
90b: CAM device
90c: image processing apparatus and method
91: numerical control unit
91a: storage unit
91b: calculation unit
91c: memory device
92: work door control unit
93: material layer formation control part
94: irradiation control unit
95: workbench control part
96: chuck control unit
97: conveying robot control part
98: material supply/recovery control unit
99: mobile robot control unit
100: laminated molding device
B: laser light
R: modeling area
W: three-dimensional modeling object
Detailed Description
Hereinafter, embodiments of the present invention will be described with reference to the drawings. The features shown in the embodiments described below can be combined with each other. The present invention is also independent of the features.
1. Laminate molding apparatus 100
Fig. 1 is a schematic configuration diagram of a stack molding apparatus 100 according to the present embodiment. The stack molding apparatus 100 includes: a chamber 1, a material layer forming apparatus 2, an irradiation apparatus 3, a modeling table 4, a chuck apparatus 5, a transfer robot 6, a material recovery apparatus 7, a mobile robot 8, an imaging apparatus 18, and a control apparatus 9. In the molding region R provided on the molding table 4 disposed in the chamber 1, the formation of the material layer 81 and the cured layer 82 is repeated, whereby a desired three-dimensional molded article W can be formed.
1.1. Chamber 1
The chamber 1 covers a molding region R, which is a region where a desired three-dimensional molded object W is formed. The chamber 1 is filled with an inert gas having a predetermined concentration supplied from an inert gas supply device (not shown). The inert gas in this specification is a gas that does not substantially react with the material layer 81 or the cured layer 82, and is selected according to the type of material, and nitrogen, argon, or helium can be used, for example. The inert gas containing the fumes generated when the cured layer 82 is formed is discharged from the chamber 1, and the fumes are removed in a fume collector (not shown) and supplied to the chamber 1 for reuse. The fume collector is, for example, an electrical dust collector or a filter.
A window 1a as a transmission window for the laser beam B is provided on the upper surface of the chamber 1. The window 1a is formed of a material that is transparent to the laser light B. Specifically, the material of the window 1a is selected from quartz glass, borosilicate glass, germanium, silicon, zinc selenide, crystal of potassium bromide, and the like, depending on the type of the laser light B. For example, in the case where the laser B is a fiber laser or a yttrium aluminum garnet (yttrium aluminum garnet, YAG) laser, the window 1a can include quartz glass.
Further, a contamination prevention device 17 is provided on the upper surface of the chamber 1 so as to cover the window 1a. The contamination prevention device 17 includes a cylindrical housing 17a, and a cylindrical diffusion member 17b disposed in the housing 17 a. The clean inert gas supplied to the space between the frame 17a and the diffusion member 17b fills the inside of the diffusion member 17b through the pores formed in the wall surface of the diffusion member 17b, and is ejected downward through the opening provided in the bottom surface of the frame 17 a. With this structure, it is possible to prevent smoke from adhering to the window 1a, thereby removing smoke from the irradiation path of the laser light B.
The chamber 1 is provided with a work door (not shown) that can be opened and closed under the control of the control device 9. When the bottom plate 83 is carried into the chamber 1 or when the bottom plate 83 and the molded article W are taken out of the chamber 1, the work door is opened, and the carrying robot 6 enters and exits the chamber 1 to carry in and out the work. When the carrying-in and carrying-out operation is not performed, particularly during molding, the operation door is closed.
1.2. Material layer forming apparatus 2
The material layer forming apparatus 2 supplies material powder to the bottom plate 83 placed in the molding region R to form the material layer 81. As shown in fig. 1 to 4, the material layer forming apparatus 2 is provided inside the chamber 1, and includes a base 21 and a coater head 22 disposed on the base 21. The applicator head 22 is configured to be reciprocally movable in a horizontal uniaxial direction by an applicator head driving device 23.
As shown in fig. 3 and 4, the applicator head 22 includes a material accommodating portion 22a, a material supply port 22b, and a material discharge port 22c. The material supply port 22b is provided on the upper surface of the material storage portion 22a, has a rectangular shape extending in the longitudinal direction of the material storage portion 22a, and serves as a receiving port for the material powder supplied from the material supply unit 10 to the material storage portion 22 a. The material discharge port 22c is provided on the bottom surface of the material housing portion 22a, and discharges the material powder in the material housing portion 22 a. The material discharge port 22c has a slit shape extending in the longitudinal direction of the material accommodating portion 22 a. A flat plate-shaped blade 22fb and a flat plate-shaped blade 22rb are provided on both side surfaces of the applicator head 22. The blades 22fb and 22rb planarize the material powder discharged from the material discharge port 22c, forming a material layer 81.
1.3. Irradiation device 3
As shown in fig. 1, the irradiation device 3 is disposed above the chamber 1. The irradiation device 3 irradiates the irradiation region of the material layer 81 formed in the molding region R with the laser beam B, and melts or sinters the material powder to solidify the material powder, thereby forming the solidified layer 82. The laser B can enable the material powderSintering or melting, e.g. fibre lasers, CO 2 A laser, a YAG laser. The irradiation device 3 may be configured to irradiate an electron beam instead of the laser beam B to cure the material layer 81.
1.4. Modeling workbench 4
A modeling table 4 is provided in the chamber 1, and a modeling area R is provided on the upper surface thereof. The modeling table 4 is configured to be movable up and down by a table driving mechanism 41. The table driving mechanism 41 of the present embodiment is configured using a motor as a driving source. The configuration of the table driving mechanism 41 is not limited to the example of the present embodiment, and other configurations are possible as long as the modeling table 4 can be moved in the up-down (vertical) direction.
1.5. Chuck device 5
The chuck device 5 is disposed on the molding table 4, and is configured to be capable of removably fixing the bottom plate 83 in the molding region R. The bottom plate 83 is held and fixed by the chuck device 5, and the bottom plate 83 is placed in the molding region R.
The bottom plate 83 may be fixed directly by the chuck device 5 or may be fixed via another member such as a mounting plate 84. In the present embodiment, as shown in fig. 1, 5, and 6, the bottom plate 83 is detachably fixed to the chuck device 5 via the mounting plate 84 and the tray 85. Specifically, the shaft 87 is attached to the bottom surface of the tray 85 so as to protrude downward, and the tray 85 is detachably fixed by gripping the shaft 87 by the chuck device 5. The mounting plate 84 is fixed to the tray 85 by a fixing member such as a bolt, and the bottom plate 83 is fixed to the mounting plate 84 by a fixing member such as a bolt. That is, the chuck device 5, the tray 85, the mounting plate 84, and the bottom plate 83 are arranged in this order from the lower side, and the three-dimensional molded object W is molded on the upper surface of the bottom plate 83.
As shown in fig. 6 to 8, the chuck device 5 of the present embodiment includes a chuck base 51 disposed on the modeling table 4, and a clamping unit 52 disposed on the chuck base 51.
The chuck base 51 is used to fix the chuck device 5 to the modeling table 4. In the present embodiment, four corners of the chuck base 51 having a quadrangular shape in plan view are fixed to the modeling table 4 by fixing members such as bolts.
The holding unit 52 has a substantially bottomed cylindrical shape. A plurality (four in one example) of first convex portions 52a and second convex portions 52b are provided on the upper surface of the holding unit 52 in concentric circles in a plan view, and a plurality (four in one example) of contact concave portions 52c are provided so as to be radially formed from the center in a plan view. As shown in fig. 6, a plurality of balls 52d are disposed at equal intervals in the circumferential direction of the shaft 87 in the holding unit 52, and serve as locking members for locking the shaft 87.
As shown in fig. 6 and 7, the shaft 87 includes a locking pin 87a and a locking portion 87b provided outside the locking pin 87 a. A screw portion is formed on the upper end side of the clip 87a, and the clip 87a is attached to the tray 85 by screwing the screw portion into a screw hole formed in the bottom surface of the tray 85. The lower end of the locking pin 87a is inserted into the insertion hole 52e of the holding unit 52, and the ball 52d of the holding unit 52 is engaged with the recess 87c of the locking portion 87b, whereby the shaft 87 is locked. Thereby, the tray 85 is fixed to the chuck device 5.
Further, in the present embodiment, the positioning plate 86 is interposed between the tray 85 and the holding unit 52. The positioning plate 86 is fixed to the bottom surface of the tray 85 using a fixing member such as a bolt. The positioning plate 86 is provided with a plurality of (four in one example) first openings 86a and second openings 86b, respectively. The first opening 86a and the second opening 86b are provided at positions overlapping the first convex portion 52a and the second convex portion 52b of the holding unit 52 in plan view, respectively, and the positioning plate 86 is positioned in the horizontal direction by the first convex portion 52a being inserted into the first opening 86a and the second convex portion 52b being inserted into the second opening 86b.
A plurality of (four in one example) support legs 86c are attached to the lower surface of the positioning plate 86 by using attachment shafts 86 d. The support leg 86c is attached to a position overlapping the contact concave portion 52c in a plan view, and the positioning plate 86 is positioned in the vertical direction by the bottom surface of the support leg 86c coming into contact with the contact concave portion 52 c. By attaching the positioning plate 86 to the tray 85, the mounting plate 84 and the bottom plate 83 fixed to the tray 85 can be arranged at predetermined positions in the horizontal direction and the vertical direction with high accuracy when the tray 85 is fixed by the chuck device 5.
In the present embodiment, the bottom plate 83 is fixed to the chuck device 5 via other members (the mounting plate 84 and the tray 85). In this structure, the mounting portion such as the screw hole for mounting the shaft 87 or the positioning plate 86 may be formed in the other member, and the other member may be partially or entirely removed from the bottom plate 83 after molding and reused. Therefore, since it is not necessary to provide an attachment portion on the bottom plate 83 according to the form of the chuck device 5, the bottom plate 83 can be manufactured at a lower cost.
As shown in fig. 5 and 6, in the present embodiment, the side surface of the chuck device 5 is covered with the chuck cover 53. The chuck cover 53 includes an outer cover 54 and an inner cover 55. The outer cover 54 covers at least a portion of the side face of the inner cover 55, and the inner cover 55 covers the side face of the chuck device 5. As a material of the chuck cover 53, metal, resin, or the like can be used.
Specifically, as shown in fig. 6 and 8, the inner cover 55 includes a cylindrical inner coating portion 55a and a flange portion 55b extending radially outward from a lower end of the inner coating portion 55 a. The inner coating portion 55a covers the side surface of the holding unit 52 of the chuck device 5. The inner cover 55 is fixed to the chuck base 51 in the flange portion 55b. The outer cover 54 includes a cylindrical outer cover portion 54a and an upper surface portion 54b extending radially inward from an upper end of the outer cover portion 54 a. The outer coating portion 54a covers a part of the upper side of the side surface of the inner coating portion 55 a. The outer cover 54 is fixed to the tray 85 in the upper surface portion 54b in a state where the upper surface of the upper surface portion 54b is in contact with the bottom surface of the tray 85. The outer cover 54 and the inner cover 55 are disposed so that the outer coating portion 54a and the inner coating portion 55a are coaxial. With this structure, when the fixation of the bottom plate 83 by the chuck device 5 is released during or after the molding is completed, the invasion of the surplus material into the inside of the chuck device 5, particularly the holding unit 52, can be prevented.
As shown in fig. 6, a gap G is provided between the outer cover 54 and the inner cover 55. Specifically, the gap G is provided by designing the outer cover 54 and the inner cover 55 so that the inner diameter D1 of the outer cover 54a and the outer diameter D2 of the inner cover 55a satisfy the condition D1 > D2. The gap G is preferably set so that the distance (in this embodiment, (D1-D2)/2) between the inner surface of the outer coating portion 54a and the outer surface of the inner coating portion 55a is 1mm to 10 mm. In this structure, the path along which the powder such as the surplus material falling from the bottom plate 83 reaches the inside of the chuck cover 53 is curved, so that the invasion of the powder can be prevented more effectively.
The structure of the chuck cover 53 is not limited to the example of the present embodiment. For example, the inner coating portion 55a and the outer coating portion 54a may be formed in a square tube shape. According to the chuck device 5 of the embodiment shown in fig. 6 to 8, no matter what process the transfer robot 6 sucks and removes the surplus material powder, the possibility of occurrence of a situation in which the surplus material powder enters the holding unit 52 and the molding cannot be continued is reduced, and thus, unmanned operation of continuous molding is supported.
1.6. Transfer robot 6
The transfer robot 6 is configured to be able to take out the molded article W molded on the bottom plate 83 from the chamber 1. In the present embodiment, after molding is completed, the balls 52d of the holding unit 52 are engaged with and disengaged from the concave portions 87c, and thereby the fixation of the tray 85 by the chuck device 5 is released. In this state, the conveying robot 6 holds a predetermined portion of the tray 85 or inserts and lifts a support bar into a support hole (not shown) provided in a side surface of the tray 85, and thereby removes the bottom plate 83 and the molded article W from the chamber 1 via the mounting plate 84, the tray 85, the shaft 87, the outer cover 54, and the work door.
The transfer robot 6 may be configured to take out the molded article W from the chamber 1, then move the molded article W to a predetermined position, and reverse the molded article W in the vertical direction. By inverting the molding W, the surplus material adhering to the molding W or the bottom plate 83 can be dropped and removed. At this time, the inverted molded article W may be placed on a finishing device (not shown) provided on the outside of the chamber 1, and the surplus material may be automatically or manually removed by finishing. As the finishing removal, for example, the following methods are listed: the suction nozzle sucks the material powder, or vibrates the molded object W to drop the material powder, and conveys the molded object W to a suction chamber (not shown) outside the chamber 1 to perform suction and removal of the powder.
When the molded article W is subjected to secondary processing, the transfer robot 6 moves the bottom plate 83 taken out of the chamber 1 and the molded article W to a secondary processing apparatus (not shown).
The transfer robot 6 of the present embodiment is also used to transfer the bottom plate 83 into the chamber 1 before molding starts. Specifically, in a stocker (not shown) provided outside the chamber 1, the conveyance robot 6 holds a predetermined portion of the tray 85 or inserts a support rod into a support hole provided in a side surface of the tray 85 and lifts the support rod while keeping the floor 83, the mounting plate 84, the tray 85, the shaft 87, and the outer cover 54 in a state of being integrated with a floor group, and carries the floor group into the chamber 1 from a work door and inserts a lower end of the shaft 87 into the holding unit 52. The balls 52d are engaged with the concave portions 87c of the inserted shafts 87, whereby the tray 85 is fixed by the chuck device 5.
1.7. Material powder supply/recovery system
Next, a supply/recovery system of the material powder including the material recovery device 7 will be described. As shown in fig. 1, a material supply unit 10 is provided near the wall surface of the chamber 1. The material supply unit 10 includes a material tank 11, a main pipe 12, and an intermediate pipe 13. The material tank 11 accommodates a novel material powder, and is supplied to the intermediate pipe 13 through the main pipe 12.
The intermediate duct 13 is movable in the up-down direction, and is configured to discharge the material powder from the intermediate duct outlet 13 a. The intermediate duct outlet 13a of the present embodiment is rectangular in shape extending in substantially the same direction as the material supply port 22b of the applicator head 22. The intermediate duct outlet 13a is configured to be openable and closable by the shutter 14. The intermediate duct outlet 13a is normally closed by the shutter 14. When replenishing the material powder, the applicator head 22 moves to a position immediately below the intermediate pipe 13, and the intermediate pipe 13 moves to a position where the intermediate pipe outlet 13a is lower than the upper end of the material housing portion 22 a. In this state, the shutter 14 is opened, replenishing the material powder.
In the present embodiment, the powder holding wall 42 is provided so as to surround the molding table 4. The material powder is held on the molding table 4 by the powder holding wall 42. A material recovery tank 70 is provided, and the material recovery tank 70 is configured to accommodate the surplus material discharged to the outside of the powder holding wall 42.
At least one powder discharge portion 70b communicating with the material recovery tank 70 is provided on the base 21 of the material layer forming apparatus 2. The surplus material or foreign matter extruded by the moving coater head 22 is discharged from the powder discharge portion 70b, guided to the chute 70e by the chute guide 70d, and accommodated in the material recovery tank 70. The powder discharge portion 70b may be configured to be openable and closable by a shutter (not shown). Further, a powder discharge portion 70a capable of discharging the material powder inside the powder holding wall 42 may be provided below the powder holding wall 42, and after the lamination molding is completed, the molding table 4 may be lowered to discharge a part of the uncured material powder, the chips, or other impurities from the powder discharge portion 70 a. In this case, the material powder discharged from the powder discharge portion 70a is guided to the chute 70e by the chute guide 70c, and is stored in the material recovery tank 70.
As shown in fig. 1, the material recovery device 7 of the present embodiment includes: a material recovery conveyor 71, an impurity removal device 73, a suction device 74, a material supply tank 76, a material drying device 77, a material supply conveyor 78, and a suction nozzle 79. The suction port 71b of the material recovery conveyance device 71 is connected to the material recovery tank 70 via a switching valve 72 by piping or the like, and the material powder containing impurities in the material recovery tank 70 is conveyed to the impurity removal device 73 by the material recovery conveyance device 71. Examples of the impurities include sputter deposition generated during irradiation and machining scraps generated by cutting. The impurity removing device 73 removes impurities from the material powder conveyed from the material recovery conveying device 71. The material powder from which the impurities are removed is contained in the material supply tub 76. The material drying device 77 dries the material powder in the material supply barrel 76. The material powder dried by the material drying device 77 is supplied into the main pipe 12 by the material supply conveyor 78 connected to the upper portion of the main pipe 12, and is reused.
The material recovery conveyor 71 and the material supply conveyor 78 have cyclone filters therein, and the exhaust ports 71a and 78a of the filters are connected to the suction device 74 via a switching valve 75 and a pipe or the like. The suction device 74 has a suction force capable of sucking gas together with solid, and is configured by using a cleaner or the like, for example. When the suction device 74 sucks the solid such as the material powder and the impurity together with the gas, the filter separates only the solid from the gas flow by the specific gravity difference and drops the solid. Thereby, the solids are conveyed, and the gas is sucked from the gas outlet 71a and the gas outlet 78a to the suction device 74. The one suction device 74 may be switchably connected to the material recovery conveyor 71 and the material supply conveyor 78 via a switching valve 75, and the one suction device 74 may be connected to the material recovery conveyor 71 and the material supply conveyor 78 independently.
The suction nozzle 79 is configured to be capable of sucking the surplus material powder on the modeling table 4. The suction nozzle 79 is housed in a housing portion (not shown) outside the chamber 1, and is held by the mobile robot 8 and moved into the chamber 1 when suction is performed.
In order to clean the chamber 1, the suction nozzle 79 may be used to suck the surplus material or chips scattered on the region other than the modeling table 4 in the chamber 1 (in other words, the outside of the modeling region R). If molding is performed in a state where surplus material or the like remains in an area outside the molding area R, an operation abnormality or a failure may occur during the automatic operation of the laminated molding apparatus 100. Such a situation can be avoided by sucking and removing the surplus material and the like in the region outside the molding region R by the suction nozzle 79.
The suction nozzle 79 of the present embodiment is connected to the suction port 71b of the material recovery conveyor 71 via a switching valve 72 by piping or the like. For example, a suction nozzle 79 may be attached to one end of a flexible hose, and the other end of the hose may be connected to the suction port 71b via the switching valve 72. The material powder sucked from the suction nozzle 79 is supplied into the main pipe 12 after the impurity removal process and the drying process are performed by the same method as described above.
The laminate molding apparatus 100 of the present embodiment includes a detecting member (not shown) capable of detecting the proportion of the material powder in the sucked object sucked by the suction nozzle 79. As the ratio of the material powder in the object to be suctioned, for example, a volume flow ratio or a mass flow ratio of the material powder in the object to be suctioned, or an area ratio in a predetermined detection region can be used. In the present embodiment, a flow sensor is provided as a detection means inside the suction nozzle 79 or a hose to which the suction nozzle 79 is attached. As an example, the flow sensor is configured to be able to detect the volume flow rate of the powder in the sucked object. Specifically, the flow sensor emits microwaves at a predetermined position inside the suction nozzle 79 or the hose, and receives the reflected waves. The frequency and amplitude of the reflected wave are changed according to the amount of powder in the sucked object passing through the predetermined position, so that the volume flow rate of the material powder in the sucked object can be detected based on the change, and the volume flow rate ratio of the material powder can be obtained. The detection result obtained by the detection means is output to the control device 9. The detection means may be configured to directly detect the proportion of the material powder in the sucked object, or may be configured to indirectly detect the proportion of the material powder. In the case of indirectly detecting, for example, the ratio of the gas in the sucked object may be detected, and the ratio of the material powder may be obtained based on the detection result.
Fig. 9a and 9b are diagrams showing the tip of the suction portion 79a of the suction nozzle 79. Fig. 9a is a front view, and fig. 9b is a right side view. The suction nozzle 79 of the present embodiment includes a suction portion 79a on the tip end side. Although not shown in fig. 9a and 9b, a grip portion that can be gripped by the mobile robot 8 is provided on the base end side of the suction nozzle 79. The suction portion 79a has a cylindrical shape in which the end face on the tip side is cut off by an inclined surface, and an opening 79b is provided in the inclined surface. The surplus material is sucked from the opening 79b.
In this structure, as shown in fig. 10, when the suction nozzle 79 is brought close to the layer containing the surplus material (surplus material layer 81 a) and a part of the opening 79b is buried in the surplus material layer 81a, the material powder is sucked from the opening 79b. At this time, the gas is sucked from the portion of the opening 79b which is not buried in the residual material layer 81 a. By sucking the material powder and the gas together, it is possible to avoid a situation in which the suction force is reduced due to an excessive proportion of solids in the sucked material, or the inside of the suction nozzle 79 and the hose is clogged.
The material collecting device 7 of the present embodiment includes a collecting mode and a suction mode as operation modes, and the material supply/collection control unit 98 of the control device 9 to be described later switches the operation modes. In the recovery mode, the material recovery device 7 recovers the material powder in the material recovery tank 70, and supplies the material powder to the material layer forming device 2 after removing the impurities. On the other hand, in the suction mode, the material recovery device 7 moves the suction nozzle 79 by the moving robot 8, and sucks the surplus material powder on the modeling table 4 by the suction nozzle 79. In the present embodiment, the material supply/recovery control unit 98 switches the switching valve 72 to switch between a recovery mode in which the material powder is conveyed by the material recovery conveyance device 71 into the material recovery tank 70 and a suction mode in which the material powder is conveyed into the suction nozzle 79.
1.8. Mobile robot 8
The moving robot 8 is configured to be able to move the suction nozzle 79. The mobile robot 8 according to the present embodiment is capable of moving from the work door into the chamber 1 by holding the suction nozzle 79 stored in the storage portion outside the chamber 1, and disposing the suction nozzle 79 at an arbitrary position in the chamber 1. Further, the moving robot 8 may change the posture (orientation and angle) of the suction nozzle 79 with respect to the molded object W by an operation such as tilting the suction nozzle 79. The mobile robot 8 may be separate from the transfer robot 6 as shown in fig. 1, or may be mounted on the transfer robot 6.
The mobile robot 8 moves the suction nozzle 79 under the control of a mobile robot control unit 99 of the control device 9 described later. The control is performed according to pre-acquired teaching data. The teaching data includes the movement path and posture of the suction nozzle 79 corresponding to the shape of the modeling object W and the height of the modeling table 4.
As shown in fig. 1, the mobile robot 8 of the present embodiment includes a robot arm 8a and a hand 8b provided at the tip of the robot arm 8a and holding the suction nozzle 79, and is driven by a driving device (not shown). The mobile robot 8 includes a torque sensor 8c capable of detecting a torque acting on the joint of the arm 8 a. The detection result of the torque by the torque sensor 8c is output to the control device 9.
1.9. Image pickup device 18
The imaging device 18 is configured to be able to acquire an image of a region (imaging region) including at least the bottom plate 83 and the molding object W. The image pickup device 18 is, for example, a charge coupled device (Charge Coupled Device, CCD) camera or a complementary metal oxide semiconductor (Complementary Metal Oxide Semiconductor, CMOS) camera. The acquired image is output to an image processing apparatus 90c described later.
As shown in fig. 1, the image pickup device 18 is provided in the chamber 1. The installation position in the chamber 1 is not particularly limited as long as it is a position that can capture the imaging region and does not interfere with the movement of the applicator head 22 or the irradiation of the laser beam B during the molding. For example, the imaging device 18 may be provided near the ceiling of the chamber 1 to capture the imaging region from above, or may be provided near the side wall of the chamber 1 to capture the imaging region from the side. The imaging device 18 may be provided so as to be movable in the chamber 1 to change the imaging area and the imaging direction, or a plurality of imaging devices 18 may be provided to perform imaging in a plurality of imaging areas and imaging directions. In addition, when the suction nozzle 79 is used to suck the surplus material in the region outside the modeling region R as described above, the region may be included in the imaging region.
The acquired image is used to determine whether the suction of the residual material by the suction nozzle 79 is completed based on the presence or absence of the residual material in the image pickup area. For this purpose, the image pickup device 18 acquires at least two of an image of the image pickup region (cleaning image) in which the bottom plate 83 and the completed molded article W are arranged in a state of being fixed in the molding region R by the chuck device 5 and in a state where no surplus material is present, and an image of the image pickup region at the time of judging that suction is completed (judgment image). By analyzing the difference between the cleaning image and the determination image by the image processing device 90c, it can be determined whether the suction of the residual material by the suction nozzle 79 is completed. In addition, in the test molding performed as a prior investigation for manufacturing the molded article W, the cleaning image can be obtained by photographing in a state where the surplus material in the chamber 1 is removed after the molding of the molded article W is completed.
1.10. Control device 9
As shown in fig. 11, the control system of the stack molding apparatus 100 includes: a computer aided design (Computer Aided Design, CAD) device 90a, a computer aided manufacturing (Computer Aided Manufacturing, CAM) device 90b, an image processing device 90c, and a control device 9. These devices are configured by arbitrarily combining hardware and software such as a central processing unit (Central Processing Unit, CPU), a random access Memory (Random Access Memory, RAM), a Read Only Memory (ROM), an auxiliary storage device, and an input/output interface. In the following, control strongly related to the present invention is described as being limited to control operations performed by the control system.
The CAD apparatus 90a creates three-dimensional shape data (CAD data) that determines the shape and size of the three-dimensional shaped object W with symmetrical shape. The CAM device 90b creates an item file defining instructions to the stack molding device 100 based on CAD data. The CAM device 90b sends the item file to the control device 9 via a communication line or a storage medium.
The image processing device 90c analyzes the cleaning image and the determination image acquired by the imaging device 18. In one example, the image processing apparatus 90c performs binarization processing for identifying a portion of the image where the material powder exists and other portions after suitably preprocessing the image. The analysis data marked each part by the binarization processing is sent to the control device 9. The binarization processing is preferably performed in pixel units of image data or unit units including a plurality of pixels.
The control device 9 controls the constituent elements of the stack molding apparatus 100 such as the material layer forming apparatus 2, the irradiation apparatus 3, the molding table 4, the chuck apparatus 5, the transfer robot 6, the material collecting apparatus 7, and the moving robot 8 according to the project file, and performs stack molding. The control device 9 includes a numerical control unit 91, a control unit 92, a control unit 93, a control unit 94, a control unit 95, a control unit 96, a control unit 97, a control unit 98, and a control unit 99, which are constituent elements of the laminated molding apparatus 100.
The numerical control unit 91 outputs operation instructions of the constituent elements of the laminated molding apparatus 100 to the respective control units 92, 93, 94, 95, 96, 97, 98 in accordance with the project file created by the CAM device 90b, and includes a storage unit 91a, a calculation unit 91b, and a memory 91c. The storage unit 91a stores the project file acquired from the CAM device 90b and teaching data for controlling the mobile robot 8. The arithmetic unit 91b executes arithmetic processing for numerical control of the constituent elements of the laminated molding apparatus 100 according to the item file. The arithmetic unit 91b outputs an operation instruction based on the teaching data to the mobile robot control unit 99. The memory 91c temporarily stores values and data during the arithmetic processing performed by the arithmetic unit 91 b.
The control unit 92, the control unit 93, the control unit 94, the control unit 95, the control unit 96, the control unit 97, the control unit 98, and the control unit 99 of the laminated molding apparatus 100 control the operations of the respective constituent elements based on the operation commands from the numerical control unit 91. Specifically, the work door control unit 92 controls the work door to be opened and closed at appropriate times. The material layer formation control section 93 controls the applicator head driving device 23 to reciprocate the applicator head 22 in the horizontal uniaxial direction. The irradiation control unit 94 controls the irradiation device 3 so that the laser beam B is irradiated to a predetermined position in the irradiation region under a predetermined condition.
The table control unit 95 controls the table driving mechanism 41 to move the modeling table 4 in the up-down direction and dispose it at a predetermined position. The chuck control unit 96 controls the gripping means 52 of the chuck device 5 to switch between fixing and releasing the bottom plate 83.
The transfer robot controller 97 controls the transfer robot 6 to carry the bottom plate 83 into the chamber 1 and to take out the bottom plate 83 and the molded article W from the chamber 1, and in addition, to reverse the molded article W taken out from the chamber 1 and to move the molded article W to the secondary processing apparatus as necessary.
The material supply/recovery control unit 98 controls the material recovery device 7 and the material supply unit 10. In addition, the operation mode of the material collecting apparatus 7 is switched.
The mobile robot controller 99 controls the mobile robot 8 to grasp the suction nozzle 79 and move it into the chamber 1. Further, the mobile robot controller 99 controls the mobile robot 8 to move the suction nozzle 79 in the chamber 1 and to suck the surplus material. In the case where the mobile robot 8 is mounted on the transfer robot 6, the transfer robot control unit 97 may have the function of the mobile robot control unit 99.
In addition to the above-described configuration, the laminated molding apparatus 100 may include a machining device (not shown) for performing machining such as cutting machining on the cured layer 82 and the molded article W as needed in the chamber 1. The machining device is configured by attaching a tool (for example, an end mill) for performing machining such as cutting to a machining head, and mechanically machining the solidified layer 82 or the molded object W by appropriately moving the machining head in the horizontal direction and the vertical direction. The tool may be rotatable by a spindle attached to the machining head.
2. Method for manufacturing three-dimensional molded article W
Next, a method for manufacturing a three-dimensional shaped object W using the stack-shaping apparatus 100 according to the present embodiment will be described with reference to fig. 12. The manufacturing method of the present embodiment includes: a placing step S1-1, a material supplying step S1-2, a solidified layer forming step S1-3, a material recovering step S1-4, a sucking step S1-5, and a taking-out step S1-6.
2.1. Mounting step S1-1
In the placement step S1-1, the bottom plate 83 is placed on the molding region R on the molding table 4. Specifically, first, the work door control unit 92 controls the work door to be opened. The transfer robot controller 97 controls the transfer robot 6 to transfer the floor set from the stocker outside the chamber 1 into the chamber 1. The transfer robot 6 transfers the floor set into the chamber 1 from the opened work door, and inserts the lower end of the shaft 87 into the insertion hole 52e of the holding unit 52. In this state, the chuck control unit 96 controls the gripping unit 52 of the chuck device 5 to engage the balls 52d with the locking portions 87b of the shaft 87. As a result, as shown in fig. 14, the bottom plate 83 is placed in the molding region R in a state of being detachably fixed to the chuck device 5. The side surface of the chuck device 5 is covered with a chuck cover 53 including an outer cover 54 and an inner cover 55.
After the floor 83 is placed, the transfer robot controller 97 controls the transfer robot 6 to retract outside the chamber 1, and the work gate controller 92 closes the work gate. Thereafter, an inert gas is supplied from an inert gas supply device into the chamber 1 and filled with the inert gas. This enables the molding to be started.
2.2. Material supply step S1-2
In the material supply step S1-2, the material powder is supplied and stored into the material storage portion 22a of the material layer forming apparatus 2. Specifically, the material layer formation control unit 93 controls the applicator head driving device 23 to move the applicator head 22 directly below the intermediate pipe 13. In this state, the material supply/recovery control unit 98 controls the material supply unit 10, opens the shutter 14, and supplies the material powder into the material storage unit 22 a. At the time point when a sufficient amount of the material powder is supplied, the material supply/recovery control section 98 closes the shutter 14 to stop the supply. Thereafter, the material layer formation control section 93 controls the applicator head driving device 23 to move the applicator head 22 to the molding region R. The material supply step S1-2 is performed a plurality of times in time from the start to the completion of molding to replenish the material powder into the material housing portion 22 a.
2.3. Solidified layer forming step S1-3
Next, a solidified layer forming step S1-3 is performed. In the cured layer forming step S1-3, the cured layer 82 is laminated by repeating the material layer forming step S1-3-1 of forming the material layer 81 by supplying the material powder onto the base plate 83 and the curing step S1-3-2 of forming the cured layer 82 by irradiating the predetermined irradiation region of the material layer 81 with the laser beam B.
Specifically, first, the table control unit 95 controls the table driving mechanism 41 to place the modeling table 4 at a predetermined height. In this state, the material layer formation control section 93 controls the applicator head driving device 23 to move the applicator head 22 from the left side to the right side in fig. 14. Thereby, the first material layer 81 is formed on the bottom plate 83. Next, the irradiation control unit 94 controls the irradiation device 3 to irradiate the predetermined irradiation region of the first layer material layer 81 with the laser beam B or the electron beam. Thus, as shown in fig. 15, the first layer material layer 81 is cured to obtain a first cured layer 82.
Then, a second material layer forming step S1-3-1 is performed. After the first cured layer 82 is formed, the stage control unit 95 controls the stage driving mechanism 41 to lower the height of the molding stage 4 by an amount equivalent to one layer of the material layer 81. In this state, the material layer formation control section 93 controls the applicator head driving device 23 to move the applicator head 22 from the right side to the left side of the molding region R in fig. 15. Thereby, the second layer material layer 81 is formed so as to cover the first cured layer 82. Then, a second curing process S1-3-2 is performed. The second layer 81 is cured by irradiating a predetermined irradiation region of the second layer 81 with laser light B in the same manner as described above, thereby obtaining a second cured layer 82.
The material layer forming step S1-3-1 and the curing step S1-3-2 are repeated, and a plurality of cured layers 82 are laminated until a desired three-dimensional modeling object W is obtained. The adjoining cured layers 82 are firmly affixed to each other. In addition, during or after molding, cutting processing or the like by a machining device is performed as needed.
2.4. Material recovery step S1-4
The material recovery step S1-4 is performed in parallel with the solidified layer forming step S1-3. In the material recovery process S1-4, the material recovery device 7 operates in a recovery mode. Specifically, the material supply/recovery control unit 98 switches the switching valve 72 so that the material powder conveyance source by the material recovery conveyance device 71 becomes the material recovery tank 70. The material recovery conveying device 71, the impurity removing device 73, the suction device 74, the material supply tank 76, the material drying device 77, and the material supply conveying device 78 are operated to remove impurities from the material powder containing impurities in the material recovery tank 70, dry the material powder, and supply the material powder into the main pipe 12.
2.5. Suction process S1-5
After the molding is completed, the suction process S1-5 is performed. In the suction step S1-5, the surplus material on the modeling table 4 is sucked by the suction nozzle 79. Specifically, first, the work door control unit 92 controls the work door to be opened. Next, the mobile robot controller 99 controls the mobile robot 8 to grasp the suction nozzle 79 and move it from the work gate into the chamber 1. In addition, in the suction process S1-5, the material recovery device 7 is operated in a suction mode. The material supply/recovery control unit 98 switches the switching valve 72 so that the source of the material powder carried by the material recovery carrying device 71 is the suction nozzle 79.
As shown in fig. 16, the modeling table 4 is lowered by a height Hw corresponding to the total thickness of the material layers 81 formed on the bottom plate 83 from the start to the completion of modeling. In the following description, as shown in fig. 14 and 16, the position (height) of the modeling table 4 in the up-down direction is represented by a single axis coordinate system along the up-down direction with the position of the upper surface of the modeling table at the start of modeling as the origin. The position of the modeling table 4 at the start time point of modeling shown in fig. 14 is h=0, and the position of the modeling table 4 at the finish time point of modeling shown in fig. 16 is h= -Hw.
As shown in fig. 16, in a state where the position of the modeling table 4 is h= -Hw, the mobile robot control unit 99 controls the mobile robot 8 to move the suction nozzle 79, and starts suction of the surplus material by the suction nozzle 79. When sucking the surplus material, the control device 9 alternately repeats the operation of controlling the table driving mechanism 41 by the table control unit 95 to raise the modeling table 4 by a predetermined raising amount Δh (raising step S1-5-1) and the operation of controlling the mobile robot 8 by the mobile robot control unit 99 to move the suction nozzle 79 in accordance with the teaching data and simultaneously sucking the surplus material powder (surplus material sucking step S1-5-2).
An example of such repetitive operations will be described. Before the molded article W is manufactured, the movement path and posture of the suction nozzle 79 corresponding to the molded article W are acquired for each amount of elevation Δh of the molding table 4 as teaching data. For example, when Δh=50 mm, the movement path and posture (operation pattern P1) of the suction nozzle 79 corresponding to each position of the modeling table 4 from the position h= -Hw to the position h=0 are obtained as the operation pattern P1, the operation pattern P2, the operation pattern P3, the operation pattern P4, the operation pattern Pn, and the movement path and posture (operation pattern P4) of the modeling table 4 from the position h= -hw+150mm, such as the movement path and posture (operation pattern P1) of the modeling table 4 from the position h= -Hw to the position h=50 mm, the movement path and posture (operation pattern P2) of the modeling table 4 from the position h= -hw+100mm, and the movement path and posture (operation pattern P3) of the modeling table 4 from the position h= -Hw to the position h=0.
The mobile robot control unit 99 first performs the first residual material suction step S1-5-2 with the modeling table 4 at the position h= -Hw. Specifically, the suction nozzle 79 is moved in accordance with the operation pattern P1 by controlling the mobile robot 8, and the surplus material is sucked from the upper surface side of the surplus material layer 81 a. At the point in time when the movement in the operation pattern P1 is completed, the mobile robot control unit 99 outputs a completion signal to the numerical control unit 91.
Upon receiving the completion signal, the numerical control unit 91 outputs an operation command for raising the modeling table 4 to the table control unit 95. In the first raising step S1-5-1, the stage control unit 95 controls the stage driving mechanism 41 to raise the modeling stage 4 by an amount Δh to a position h= -hw+50 mm. Thereby, the upper surface of the surplus material layer 81a rises. In this state, the second residual material suction process S1-5-2 is performed. The mobile robot control unit 99 controls the mobile robot 8 to move the suction nozzle 79 in accordance with the operation pattern P2, and sucks the surplus material from the upper surface side of the surplus material layer 81 a.
The control device 9 alternately repeats the raising step S1-5-1 and the residual material sucking step S1-5-2 until the modeling table 4 reaches the position h=0.
The teaching data is obtained by recording the position and posture of the suction nozzle 79 when the suction nozzle 79 is moved by manually operating the mobile robot 8 and the surplus material is sucked, and indicates an appropriate movement path and posture of the suction nozzle 79 according to the shape of the molded object W and the height of the molding table 4. By performing suction of the surplus material while moving the suction nozzle 79 in accordance with the teaching data, the surplus material can be removed more reliably and efficiently.
The lifting amount Δh of the modeling table 4 in one lifting operation in the suction step S1-5 is preferably 20mm to 80mm, more preferably 35mm to 65mm, for example 50mm. If the amount of rise in one rise operation is too small, the rise operation may be frequent, and the efficiency of the suction process S1-5 may be lowered. On the other hand, if the amount of elevation is too large, the height of the upper surface of the surplus material layer 81a may exceed the upper end of the powder holding wall 42, and may not be held on the molding table 4.
In the present embodiment, the control device 9 determines whether or not there is any remaining material powder using the image acquired by the imaging device 18. Specifically, as described above, a cleaning image is acquired in advance in the test molding, and in the suction process S1-5, when the suction is completed in each of the operation patterns P1, P2, P3, P4, & gtPn by the suction nozzle 79 and the molding table 4 is raised to the position H=0, the determination image is acquired by the image pickup device 18. The image processing device 90c analyzes the cleaning image and the determination image. The numerical controller 91 of the control device 9 compares these analysis data to determine whether or not there is any residual material in the imaging region.
As an example, the number of pixels or cells of a portion marked as having a material powder by the binarization processing is counted in the analysis data of the cleaning image and the determination image, respectively. When the difference (Nj-Nc) between the count Nc in the analysis data of the cleaning image and the count Nj in the analysis data of the determination image is equal to or less than a predetermined value, it is determined that the remaining material is sucked in its entirety. On the other hand, when the difference (Nj to Nc) is larger than the predetermined value, it is determined that the surplus material remains in the imaging region, and suction by the suction nozzle 79 is performed again. At the time of re-suction, the suction nozzle 79 may be moved in accordance with the final operation pattern Pn of the rising of the modeling table 4, or may be moved in accordance with the re-suction operation pattern acquired as teaching data.
By determining whether or not surplus material is present based on the acquired image obtained by the imaging device 18 in this way, surplus material in the imaging region including the bottom plate 83 and the molded object W can be reliably removed. In particular, even when the suction by the suction nozzle 79 is wide due to the relatively large size of the bottom plate 83 and the molded article W or the suction of the surplus material in the region outside the molding region R, the presence or absence of the surplus material can be determined and reliably removed.
Further, the control device 9 of the present embodiment determines whether or not the remaining material powder is present based on the detection result of the detection means. Specifically, at a point in time when the ratio of the material powder in the sucked object sucked by the suction nozzle 79 is approximately 0, it is determined that all the surplus material in the image pickup area is sucked.
In the determination based on the acquired image of the imaging device 18, in addition to the case where it is difficult to determine whether or not there is an excess material in a detail portion such as a fine groove portion of the molded object W, there is a case where the determination accuracy is lowered depending on the type of material powder or the illumination in the chamber 1. In this case, the determination can be made by using the detection result of the detection means.
The determination of the presence or absence of the surplus material based on the acquired image of the image pickup device 18 and the determination of the presence or absence of the surplus material based on the detection result of the detection means may be performed only either, and preferably, they are used in combination. By using the former, which enables a wide range of determinations, and the latter, which enables determination of detailed portions such as grooves and is less susceptible to the type of material powder or illumination, the determination can be performed with high accuracy and the surplus material can be removed more reliably.
In addition, the suction nozzle 79 may be moved in response to a stop of the suction operation, a correction of the movement path, or the like based on the detection result of the torque sensor 8 c. When the suction nozzle 79 contacts the molded object W or the bottom plate 83, the torque acting on the joint portion of the robot arm 8a becomes large. When the detected value of the torque is large, for example, the suction operation is temporarily stopped, or the movement path is corrected so that the suction nozzle 79 is away from the molded object W or the bottom plate 83, whereby damage to the molded object W can be avoided.
After the suction is completed, the mobile robot controller 99 controls the mobile robot 8 to move the suction nozzle 79 from the work door to the outside of the chamber 1 and store it in the storage unit. This completes the suction step S1-5.
2.6. Extraction procedure S1-6
After the suction step S1-5 is completed, the extraction step S1-6 is performed to extract the bottom plate 83 and the molded article W molded on the bottom plate 83 from the chamber 1. Specifically, first, the chuck control unit 96 controls the gripping unit 52 of the chuck device 5 to engage and disengage the balls 52d from the locking portions 87b, and releases the fixation of the bottom plate 83 by the chuck device 5. Next, the transfer robot controller 97 controls the transfer robot 6 to take out the bottom plate 83 and the molded article W from the mounting plate 84, the tray 85, the shaft 87, the outer cover 54, and the chamber 1.
After the molded article W is taken out from the chamber 1, the transfer robot controller 97 may control the transfer robot 6 to invert the molded article W in the vertical direction to drop the surplus material, or to place the inverted molded article W in the finishing apparatus to finish and remove the surplus material. In the case of performing the secondary processing, the transfer robot controller 97 controls the transfer robot 6 to move the molded article W to the secondary processing apparatus, and then performs the secondary processing step S1-7. In this case, by introducing the fixing device having the same configuration as the chuck device 5 into the secondary processing device, the transfer robot 6 can be controlled, and the bottom plate 83 and the molded article W are fixed via the mounting plate 84 and the tray 85 to be arranged in the fixing device, similarly to the fixation to the chuck device 5 in the placing step S1-1. The placement of the molded article W in the secondary processing apparatus can be automated, and high-precision secondary processing can be performed while ensuring arrangement precision equivalent to that in the placement of the molded article W in the molding region R.
After the completion of the take-out step S1-6, the three-dimensional modeling object W is sequentially manufactured by repeating the above steps. In this configuration, since the removal of the surplus material is automatically performed by the suction nozzle 79 after the molding is completed, the unmanned removal of the molded article W from the chamber 1 can be achieved.
3. Acquisition method of teaching data
Next, a teaching method for acquiring teaching data will be described. The teaching method of the present embodiment includes: a placement step S2-1, a material supply step S2-2, a molding step S2-3, a recording step S2-4, and a raising step S2-5. Acquisition of teaching data obtained by the teaching method is performed before the manufacturing of the build object W (for example, in the test build). In the following, a case where teaching data is acquired by using the stack molding apparatus 100 will be described as an example, and other stack molding apparatuses can be used.
In the placing step S2-1, the bottom plate 83 is detachably fixed by the chuck device 5 disposed on the molding table 4, and the bottom plate 83 is placed on the molding region R, which is a region of the molding object W provided on the molding table 4. The placing step S2-1 is performed in the same manner as the placing step S1-1 in the method for manufacturing the molded article W.
In the material supply step S2-2, the material powder is supplied to and stored in the material storage portion 22a of the material layer forming apparatus 2. The material supply step S2-2 is performed in the same manner as the material supply step S1-2 in the method for producing the molded article W.
In the molding step S2-3, a material layer forming step S2-3-1 of forming the material layer 81 by supplying a material powder onto the base plate 83 and a curing step S2-3-2 of forming the cured layer 82 by irradiating a predetermined irradiation region of the material layer 81 with a laser beam B or an electron beam are repeatedly performed, whereby the cured layer 82 is laminated to mold a three-dimensional molded article. The material layer forming step S2-3-1 and the curing step S2-3-2 are performed in the same manner as the material layer forming step S1-3-1 and the curing step S1-3-2 in the curing layer forming step S1-3 in the method for producing the molded article W, respectively.
After the molding in the molding step S2-3 is completed, the recording step S2-4 and the raising step S2-5 are performed. In the recording step S2-4, the operator manually operates the mobile robot 8 to move the suction nozzle 79 and suction the surplus material powder on the modeling table 4, and the position coordinates and the posture of the suction nozzle 79 at this time are transferred to the control device 9 and recorded.
Specifically, after the molding is completed, the suction nozzle 79 is moved by manually operating the moving robot 8 in a state where the position of the molding table 4 is h= -Hw, and the surplus material is sucked from the upper surface side of the surplus material layer 81 a. At this time, the position and posture of the suction nozzle 79 are adjusted so that the suction nozzle 79 does not contact the molding material W or the bottom plate 83, and the surplus material existing in the recess or the like of the molding material W can be efficiently sucked, and the suction nozzle 79 is moved until the surplus material of the predetermined depth Δd is removed from the upper surface side of the surplus material layer 81 a. The depth Δd is set to be equal to the rising amount Δh of the modeling table 4. The position coordinates and the posture of the suction nozzle 79 in this movement are recorded at a plurality of points as an operation pattern P1. The movement path of the suction nozzle 79 between the points may be, for example, a straight line (linear interpolation) connecting the two points, or may be created based on shape data of the desired three-dimensional modeling object W.
After the surplus material of the depth Δd is removed in the first recording step S2-4, the modeling table 4 is raised by a predetermined raising amount Δh in the raising step S2-5. Thereby, the upper surface of the surplus material layer 81a rises. In this state, the second recording process S2-4 is performed. As in the first time, the suction nozzle 79 is moved by manually operating the mobile robot 8, the surplus material of the depth Δd is sucked from the upper surface side, and the position coordinates and the posture of the moving suction nozzle 79 are recorded as the operation pattern P2 at a plurality of points.
The recording step S2-4 and the raising step S2-5 are repeated until the modeling table 4 reaches the position h=0, the suction of the surplus material is completed, thereby acquiring teaching data including the movement path and posture of the suction nozzle 79 corresponding to the heights of the molded article W and the molding table 4 as an operation pattern P1 action pattern P2, action pattern P3, action pattern P4, & & gtaction pattern Pn. Thus, teaching data including an appropriate movement path and posture of the suction nozzle 79 corresponding to the shape of the molded object W and the height of the molding table 4 can be obtained.
In this way, the movement of the suction nozzle 79 based on the operation pattern obtained by the manual operation of the mobile robot 8 is significant particularly in the suction removal of the surplus material or the like in the state where the modeling table 4 is at the uppermost position (position h=0). By moving the suction nozzle 79 in an appropriate movement path and posture when the modeling table 4 reaches the uppermost position, not only the situation in which the surplus material or the like remains on the modeling table 4 and adversely affects the next modeling but also the surplus material or the like scattered outside the modeling area R can be efficiently removed, and therefore, the cleaning operation in the chamber 1 for maintenance can be automated.
The number of dots included in one operation pattern can be appropriately set according to the size or shape of the molding object W and the molding table 4, and is, for example, 5 to 40, preferably 10 to 20. If the number of dots is too small, the efficiency of removing the surplus material may be reduced or the contact with the molded object W or the bottom plate 83 may be increased when the suction nozzle 79 is moved based on the teaching data. If the number of points is excessive, the control of the mobile robot 8 may become complicated.
In addition, in the recording step S2-4, the detection result of the torque sensor 8c may be recorded in addition to the position coordinates and the posture of the suction nozzle 79. By removing the data of the points with large torque values from the recorded position coordinates and posture, an operation pattern with less contact with the molded object W or the bottom plate 83 can be created.
4. Other embodiments
The present invention can also be implemented in the following manner.
In the above embodiment, the cleaning image is obtained by molding the molded object W in the test molding, and the molded object W is molded in the molding step S2-3 of the teaching method, but the present invention is not limited to this configuration. For example, the cleaning image and the teaching data are acquired for each of a plurality of model objects having different sizes, and the cleaning image and the teaching data of the model object having the closest size among the plurality of model objects may be used when manufacturing the model object W. In this configuration, the cleaning image and the teaching data may be acquired for several modeling objects having a representative size, and the cleaning image and the teaching data need not be acquired for each modeling object W.
While various embodiments of the present invention have been described above, these are presented as examples and are not intended to limit the scope of the invention. The novel embodiment can be implemented in various other modes, and various omissions, substitutions, and changes can be made without departing from the spirit of the invention. The embodiments and modifications thereof are included in the scope and gist of the invention, and are included in the invention described in the claims and their equivalents.
Claims (12)
1. A stack molding apparatus comprising: a molding table, a chamber, a material layer forming apparatus, a chuck apparatus, a material recovery apparatus, a transfer robot, a moving robot, and a control apparatus,
the modeling workbench is configured to be capable of up-and-down movement by a workbench driving mechanism,
the chamber covers a modeling area which is an area provided on the modeling workbench and formed with a modeling object,
the material layer forming device supplies material powder to a bottom plate placed in the molding area to form a material layer,
the chuck device is arranged on the modeling workbench and is configured to be capable of freely assembling and disassembling the bottom plate and fixing the bottom plate in the modeling area,
The material recovery device comprises a suction nozzle capable of sucking the remaining material powder on the modeling workbench,
the transfer robot is configured to take out the base plate and the molded object molded on the base plate from the chamber,
the moving robot is configured to move the suction nozzle,
the control device alternately and repeatedly controls the table driving mechanism to raise the modeling table by a prescribed raising amount and controls the mobile robot to move the suction nozzle according to teaching data and simultaneously sucks the remaining material powder,
the teaching data includes a movement path and a posture of the suction nozzle corresponding to a shape of the modeling object and a height of the modeling table.
2. The stack molding apparatus according to claim 1, comprising an imaging device,
the imaging device is configured to be able to acquire an image of an area including at least the base plate and the molded object,
the control device determines whether the material powder remains using the image acquired by the imaging device.
3. The laminate molding apparatus according to claim 1 or 2, comprising a detecting means,
The detecting means is capable of detecting a proportion of the material powder in the sucked object sucked by the suction nozzle,
the control device determines whether or not the material powder remains based on the ratio of the material powder.
4. The stack molding apparatus according to claim 3, wherein,
the detection component is a flow sensor.
5. The stack molding apparatus according to claim 1 or 2, comprising:
a powder holding wall surrounding the modeling table and configured to hold the material powder on the modeling table; and
a material recovery tank configured to store the remaining material powder discharged to the outside of the powder holding wall,
the material recovery device includes a recovery mode and a suction mode as operation modes,
the control device is configured to switch the operation mode,
the material recovery device is configured to: in the recovery mode, the material powder in the material recovery tank is recovered, and the material powder is supplied to the material layer forming apparatus after removing the impurities, and in the suction mode, the suction nozzle is moved by the moving robot, the remaining material powder on the modeling table is sucked by the suction nozzle, and the impurities are removed from the material powder.
6. The stack molding apparatus according to claim 1 or 2, wherein,
the sides of the chuck means are covered by a chuck cover,
the chuck cover includes an outer cover and an inner cover,
the outside cover covers at least a portion of a side surface of the inside cover,
the inner cover covers the side of the chuck device.
7. The stack molding apparatus according to claim 1 or 2, wherein,
the chuck device fixes the base plate via a mounting plate.
8. The stack molding apparatus according to claim 1 or 2, wherein,
the suction nozzle includes a suction portion at a front end side,
the suction part has a cylindrical shape formed by cutting the end face of the front end side by an inclined face,
an opening is provided in the inclined surface.
9. The stack molding apparatus according to claim 1 or 2, wherein,
the transfer robot is configured to be capable of transferring the floor to the chamber.
10. The stack molding apparatus according to claim 1 or 2, wherein,
the transfer robot is configured to invert the molded object after the molded object is taken out of the chamber.
11. A manufacturing method is a manufacturing method of a three-dimensional modeling object, comprising:
A mounting step, a solidified layer forming step, a suction step, and a take-out step,
in the loading step, the base plate is removably fixed by a chuck device disposed on the molding table, and the base plate is loaded on a molding region which is a region where a molded object is formed and is provided on the molding table,
in the step of forming a cured layer, a step of forming a material layer by supplying a material powder onto the base plate and a step of forming a cured layer by irradiating a predetermined irradiation region of the material layer with a laser beam or an electron beam are repeated, whereby the cured layers are laminated,
in the suction step, the molding table is raised by a predetermined amount by a table driving mechanism and the remaining material powder is sucked while the suction nozzle is moved by a moving robot according to teaching data are alternately repeated,
in the removing step, the base plate and the molded object molded on the base plate are removed from a chamber covering the molding region by a transfer robot,
the teaching data includes a movement path and a posture of the suction nozzle corresponding to a shape of the modeling object and a height of the modeling table.
12. A teaching method for acquiring teaching data for use in sucking surplus material powder generated in a laminated molding of a three-dimensional molded object with a suction nozzle, the teaching method comprising:
a loading step, a molding step, a recording step, and a raising step,
in the loading step, the base plate is removably fixed by a chuck device disposed on the molding table, and the base plate is loaded on a molding area which is an area for forming a molded object and is provided on the molding table,
in the molding step, a material layer forming step of forming a material layer by supplying a material powder onto the base plate and a curing step of forming a cured layer by irradiating a predetermined irradiation region of the material layer with a laser beam or an electron beam are repeatedly performed, whereby the cured layer is laminated to mold a three-dimensional molded article,
in the recording step, the suction nozzle is moved by manually operating a moving robot, the surplus material powder on the molding table is sucked, the position coordinates and the posture of the suction nozzle are recorded,
in the raising step, the modeling table is raised by a predetermined raising amount,
By repeating the recording step and the raising step, the teaching data including the movement path and posture of the suction nozzle corresponding to the shape of the molded object and the height of the molding table is acquired.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2022161100A JP2024054693A (en) | 2022-10-05 | 2022-10-05 | Layered modeling device, method for manufacturing three-dimensional object, and teaching method |
| JP2022-161100 | 2022-10-05 |
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| Publication Number | Publication Date |
|---|---|
| CN117841356A true CN117841356A (en) | 2024-04-09 |
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| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN202311112359.3A Pending CN117841356A (en) | 2022-10-05 | 2023-08-31 | Laminated modeling apparatus, method for manufacturing three-dimensional modeling object, and teaching method |
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| Country | Link |
|---|---|
| JP (1) | JP2024054693A (en) |
| CN (1) | CN117841356A (en) |
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2022
- 2022-10-05 JP JP2022161100A patent/JP2024054693A/en active Pending
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