JP6978350B2 - Work posture adjustment method, model manufacturing method and manufacturing equipment - Google Patents

Description

The present invention relates to a work posture adjusting method, a method for manufacturing a modeled object, and a manufacturing apparatus.

In recent years, the needs for 3D printers as a means of production have been increasing, and research and development have been carried out for practical use in the aircraft industry and the like, especially for application to metal materials. A 3D printer using a metal material melts a metal powder or a metal wire by using a heat source such as a laser or an arc, and laminates the molten metal to form a modeled object.

For example, as a technique for adjusting the posture of the work when modeling a modeled object, a probe-type touch sensor attached to the tool head and a displacement detection sensor in the reference three-axis direction provided in advance in the machine tool are used for the work. There is one that detects a posture and adjusts the posture of the work by a posture adjuster controlled by a controller based on the detection result (see Patent Document 1).

Japanese Unexamined Patent Publication No. 10-138575

By the way, when a work made of columnar steel bars having a circular cross-sectional view is erected and a welded bead is formed on the peripheral surface of the work to form a modeled object, an error occurs in the stacking position of the welded bead due to the inclination of the work. There is a risk that the quality will deteriorate. This error in the stacking position increases as the work becomes larger.
According to the posture adjustment technique described in Patent Document 1, it is possible to adjust the posture of the work, but since a displacement detection sensor in the reference 3-axis direction is required in addition to the touch sensor, the equipment cost increases. ..

An object of the present invention is a work posture adjusting method capable of adjusting the posture of a work having a circular cross section with high accuracy while suppressing equipment costs, and a method for laminating a welded bead on the work to manufacture a high-quality model. It is an object of the present invention to provide a manufacturing method and a manufacturing apparatus for a modeled object.

The present invention has the following configuration.
(1) The tool is moved along the peripheral surface of a columnar work having a circular shape in cross section supported by the support mechanism to form a welded bead in which the filler metal is melted and solidified on the peripheral surface of the work. It is a work posture adjustment method that adjusts the posture of the work when modeling an object.
Position detection processing for detecting the position by bringing the tool into contact with the peripheral surface of the work at a plurality of circumferential positions in the axial position which are a plurality of axial positions of the work.
Coordinate calculation processing to calculate the coordinates of the detected position, and
Inclination calculation processing that calculates the inclination of the work from the coordinates of the calculated position,
A posture adjustment process for adjusting the posture of the work to a preset posture by the support mechanism based on the calculated inclination of the work, and
Work posture adjustment method including.
(2) A method for manufacturing a modeled object in which a welded bead is formed around the work whose posture is adjusted by the work attitude adjusting method of (1) above to produce a modeled object.
(3) A support mechanism that supports a columnar workpiece with a circular cross-sectional view,
A tool for forming a welded bead by melting and solidifying a filler metal,
A movement mechanism for moving the tool and
A controller that controls the movement mechanism and moves the tool along the peripheral surface of the work to form a welded bead in which the filler metal is melted and solidified on the peripheral surface of the work to form a modeled object.
Equipped with
The controller
By controlling the movement mechanism, the tool is brought into contact with the peripheral surface of the work to detect the position at a plurality of circumferential positions in the axial position, which are a plurality of axial positions of the work. death,
Calculate the coordinates of the detected position and
The inclination of the work is calculated from the coordinates of the calculated position,
A device for manufacturing a modeled object that controls the support mechanism based on the calculated inclination of the work and adjusts the posture of the work to a preset posture.

According to the present invention, it is possible to adjust the posture of a work having a circular cross section with high accuracy while suppressing the equipment cost, and it is possible to manufacture a high-quality model by laminating a welded bead on the work.

It is a schematic schematic block diagram of the manufacturing system which forms a welded bead on a work and manufactures a model. It is a side view of the work supported by a support mechanism. It is a schematic perspective view of a modeled object in which a welded bead is laminated on a work. It is a schematic side view of the work supported by the support mechanism explaining the work posture adjustment method. It is a schematic side view of the work supported by the support mechanism explaining the work posture adjustment method. It is a schematic side view of the work supported by the support mechanism explaining the work posture adjustment method. It is the schematic perspective view of the work explaining the position detection process. It is a schematic side view of the work explaining the position detection process.

Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings.
FIG. 1 is a schematic schematic configuration diagram of a manufacturing system in which a welded bead is formed on a work to manufacture a modeled object.
The manufacturing system 100 having this configuration includes a laminated modeling device 11, a support mechanism 16, and a controller 15 that collectively controls the laminated modeling device 11 and the support mechanism 16.

The laminated modeling device 11 has a welding robot (moving mechanism) 19 having a torch (tool) 17 on the tip shaft, and a filler material supply unit 23 that supplies the filler metal (welding wire) M to the torch 17. The torch 17 holds the filler metal M in a state of protruding from the tip.

The controller 15 has a CAD / CAM unit 31, an orbit calculation unit 33, a storage unit 35, and a control unit 37 to which these are connected.

The welding robot 19 is an articulated robot, and the filler metal M is continuously supplied to the torch 17 provided on the tip shaft. The position and posture of the torch 17 can be arbitrarily set three-dimensionally within the range of the degree of freedom of the robot arm.

The torch 17 has a shield nozzle (not shown), and shield gas is supplied from the shield nozzle. The arc welding method used in this configuration may be either a consumable electrode type such as shielded metal arc welding or carbon dioxide arc welding, or a non-consumable electrode type such as TIG welding or plasma arc welding. It will be selected as appropriate.

For example, in the case of the consumable electrode type, a contact tip is arranged inside the shield nozzle, and the filler metal M to which the melting current is supplied is held by the contact tip. The torch 17 generates an arc from the tip of the filler metal M in a shield gas atmosphere while holding the filler metal M. The filler metal M is fed from the filler metal supply unit 23 to the torch 17 by a feeding mechanism (not shown) attached to a robot arm or the like. Then, when the filler metal M that is continuously fed is melted and solidified while moving the torch 17, a linear welded bead 25 that is a molten solidified body of the filler metal M is formed on the work 20.

The heat source for melting the filler metal M is not limited to the above-mentioned arc. For example, a heat source by another method such as a heating method using both an arc and a laser, a heating method using plasma, and a heating method using an electron beam or a laser may be adopted. When heating with an electron beam or a laser, the amount of heating can be controlled more finely, the state of the welded bead can be maintained more appropriately, and the quality of the laminated structure can be further improved.

The CAD / CAM unit 31 creates shape data of the modeled object W to be manufactured, and then divides the data into a plurality of layers to generate layer shape data representing the shape of each layer. The trajectory calculation unit 33 obtains the movement trajectory of the torch 17 based on the generated layer shape data. The storage unit 35 stores data such as the generated layer shape data and the movement locus of the torch 17.

The control unit 37 drives the welding robot 19 by executing a drive program based on the layer shape data stored in the storage unit 35 and the movement locus of the torch 17. That is, the welding robot 19 moves the torch 17 while melting the filler metal M with an arc based on the movement locus of the torch 17 generated by the trajectory calculation unit 33 in response to a command from the controller 15. In addition, FIG. 1 shows a state in which a welded bead 25 is spirally formed on the peripheral surface of a columnar work 20 having a circular shape in cross section and is erected (supported) in the vertical direction to form a model W. There is.

As shown in FIG. 2, the support mechanism 16 has a positioning mechanism portion 41 and a base 43. The positioning mechanism 41 supports the base 43. A work 20 is erected on the base 43. The work 20 is arranged on the base 43 so that its central axis 20a is along the vertical direction. The support mechanism 16 is connected to the controller 15, and the positioning mechanism unit 41 is controlled by the controller 15. In the support mechanism 16, the positioning mechanism portion 41 is driven by a command from the controller 15, and the inclination of the upper surface 43a of the base 43 is adjusted.

The manufacturing system 100 having the above configuration melts and melts the filler metal M while moving the torch 17 by driving the welding robot 19 along the movement locus of the torch 17 generated from the set layer shape data. The filler metal M is supplied to the peripheral surface of the work 20. As a result, for example, as shown in FIG. 3, a model W in which a plurality of welded beads 25 are spirally formed and laminated on the peripheral surface of the work 20 is formed.

By the way, when a work 20 made of a columnar steel bar having a circular cross-sectional view is erected and a welded bead 25 is formed on the peripheral surface of the work 20 to form a model W, the welded bead 25 is formed by the inclination of the work 20. There is a risk that the quality will deteriorate due to an error in the stacking position. This error in the stacking position increases as the work 20 becomes larger.

Therefore, in the present embodiment, the work posture is adjusted to adjust the posture of the work 20 before the welded bead 25 is formed on the peripheral surface of the work 20. The work posture adjustment includes a position detection process, a coordinate calculation process, a tilt calculation process, and a posture adjustment process.

Next, the work posture adjusting method according to the present embodiment will be described.
(Position detection processing)
As shown in FIG. 4A, position detection is performed at a plurality of detection positions (points indicated by arrows and circles in FIG. 4A) P on the peripheral surface of the work 20. In this position detection, the controller 15 drives the welding robot 19 of the laminated modeling device 11, and as shown in FIG. 5A, the torch 17 is brought close to the peripheral surface of the work 20, and the filler metal M protruding from the torch 17. This is done by bringing the tip of the torch into contact with the detection position P on the peripheral surface of the work 20. The controller 15 detects the tip position of the filler metal M in contact with the detection position P of the work 20 from the position information of the welding robot 19.

The position detection to be detected by abutting the filler metal M of the torch 17 is performed at a plurality of circumferential positions of the work 20 at a plurality of axial positions of the work 20. In this example, the work is performed at two locations in the axial direction of the work 20 and at three locations in the circumferential direction.

As shown in FIGS. 5A and 5B, the axial positions are the axial positions Z1 and Z2 at the formation start position and the formation end position of the welding bead 25 on the work 20. In the present embodiment, the weld bead 25 is spirally formed from the lower side to the upper side with respect to the peripheral surface of the work 20. Therefore, the axial position of the detection position P is the axial position Z1 at the lower formation start position and the axial position Z2 at the upper formation end position. In determining the axial positions Z1 and Z2, in the controller 15, the control unit 37 uses the welding bead 25 based on the modeling diagram of the preset model W stored in the storage unit 35. The axial position coordinates of the work 20 at the formation start position and the formation end position of the above are obtained, and the coordinates of the formation start position and the formation end position are set as the axial positions Z1 and Z2.

The circumferential positions are a plurality of locations in the circumferential direction of the work 20. For example, in the axial positions Z1 and Z2 of the work 20, the circumferential positions R1, R2, and R3 are set at three equidistant circumferential positions, respectively.

When the filler metal M of the torch 17 is brought into contact with the detection position P of the work 20 obtained as described above, the control unit 37 of the controller 15 models the preset model W stored in the storage unit 35. Based on the modeling modeling diagram shown in the figure, the welding robot 19 is driven so that the filler metal M is in vertical contact with the detection position P on the peripheral surface of the work 20, and the torch 17 is moved.

(Coordinate calculation processing)
The controller 15 calculates the coordinates of the detection position P whose position is detected by the position detection process. Specifically, the coordinates of the circumferential positions R1, R2, and R3 in the axial positions Z1 and Z2 of the work 20 are calculated, respectively.

(Slope calculation process)
Next, the controller 15 calculates the inclination of the work 20 from the calculated coordinates of the contact position. Specifically, as shown in FIG. 4B, the inclination of the central axis 20a of the work 20 with respect to the vertical line X is calculated.

(Posture adjustment process)
Subsequently, the controller 15 adjusts the posture of the work 20 to a preset posture based on the calculated inclination of the work 20. In this embodiment, the work 20 is set to stand vertically. Specifically, as shown in FIG. 4C, the controller 15 drives the positioning mechanism portion 41 of the support mechanism 16 to adjust the inclination of the upper surface 43a of the base 43. As a result, the posture of the work 20 is adjusted so that the central axis 20a of the work 20 coincides with the vertical line X.

After adjusting the posture of the work 20 by the above posture adjusting method, the controller 15 melts the filler metal M while moving the torch 17 along the movement locus of the torch 17 generated from the set layer shape data. The molten filler material M is supplied to the peripheral surface of the work 20. As a result, a plurality of welded beads 25 are spirally formed and laminated on the peripheral surface of the work 20, and the modeled object W is formed.

As described above, according to the work posture adjusting method according to the present embodiment, the torch 17 is moved along the peripheral surface of the columnar work 20 having a circular shape in cross section erected on the support mechanism 16. When the welded bead 25 in which the filler metal M is melted and solidified is formed on the peripheral surface of the 20 to form the modeled object W, the work 20 can be erected in a state of being positioned with high accuracy. As a result, even if the work 20 is large, a welded bead 25 can be formed on the peripheral surface of the work 20 while suppressing an error as much as possible to form a high-quality model W. Further, since the filler metal M protruding from the torch 17 forming the welded bead 25 is brought into contact with the work 20 to detect the position, it is not necessary to separately provide a sensor for position detection, and the equipment cost can be suppressed. ..

Further, in the position detection process, the formation start position coordinates and the formation end position consisting of the axial position coordinates of the work 20 at the formation start position and the formation end position of the welded bead 25 based on the modeling diagram of the modeled object W set in advance. The coordinates are obtained, and the axial positions Z1 and Z2 that bring the filler metal M of the torch 17 into contact with the work 20 are determined from these formation start position coordinates and formation end position coordinates. As a result, the range from the formation start position to the formation end position of the welded bead 25 can be positioned with high accuracy.

Moreover, in the position detection process, the torch 17 is in contact with the filler metal M of the torch 17 perpendicularly to the detection position P on the peripheral surface of the work 20 based on the preset modeling diagram of the modeled object W. To move. As a result, the accuracy of detecting the position of the work 20 can be improved.

Then, according to the manufacturing method and the manufacturing system 100, which is a manufacturing apparatus and a manufacturing method for forming a model W by forming a welded bead 25 with respect to the work 20 whose posture is adjusted by the work posture adjusting method, the work 20 is large. Even so, it is possible to form a welded bead 25 on the peripheral surface of the work 20 while suppressing an error as much as possible to form a high-quality model W. Further, when positioning the work 20, the filler metal M protruding from the torch 17, which is a tool for forming the weld bead 25, is brought into contact with the work 20 to detect the position, so that a sensor for position detection is separately provided. There is no need, and equipment costs can be reduced.

It should be noted that the present invention is not limited to the above-described embodiment, and those skilled in the art may modify or apply the invention based on the mutual combination of the configurations of the embodiments, the description of the specification, and the well-known technique. Is also the subject of the present invention and is included in the scope for which protection is sought.
For example, the support mechanism described above is not limited to a structure that supports the work in the vertical direction, and may be a mechanism that supports the work in another direction such as in the horizontal direction.

As described above, the following matters are disclosed in the present specification.
(1) The tool is moved along the peripheral surface of a columnar work having a circular shape in cross section supported by the support mechanism to form a welded bead in which the filler metal is melted and solidified on the peripheral surface of the work. It is a work posture adjustment method that adjusts the posture of the work when modeling an object.
Position detection processing for detecting the position by bringing the tool into contact with the peripheral surface of the work at a plurality of circumferential positions in the axial position which are a plurality of axial positions of the work.
Coordinate calculation processing to calculate the coordinates of the detected position, and
Inclination calculation processing that calculates the inclination of the work from the coordinates of the calculated position,
A posture adjustment process for adjusting the posture of the work to a preset posture by the support mechanism based on the calculated inclination of the work, and
Work posture adjustment method including.
According to this work posture adjusting method, it is possible to support a columnar work having a circular shape in cross-sectional view in a state of being positioned with high accuracy. As a result, even if the work is large, it is possible to form a welded bead on the peripheral surface of the work while suppressing an error as much as possible to form a high-quality model. Further, since the position is detected by contacting the tool for forming the welded bead with the work, it is not necessary to separately provide a sensor for position detection, and the equipment cost can be suppressed.

(2) In the position detection process, the formation start position coordinates and the formation end are composed of the axial position coordinates of the work at the formation start position and the formation end position of the welded bead based on the modeling diagram of the modeled object set in advance. The work posture adjusting method according to (1), wherein the position coordinates are obtained, and the axial position where the tool is brought into contact with the work is determined from the formation start position coordinates and the formation end position coordinates.
According to this work posture adjustment method, the axial position in which the tool is brought into contact with the work is determined from the formation start position coordinates and the formation end position coordinates consisting of the axial position coordinates of the work at the formation start position and the formation end position of the welded bead. Therefore, the range from the formation start position to the formation end position of the welded bead can be positioned with high accuracy.

(3) In the position detection process, the tool is moved so that the tool is in vertical contact with the peripheral surface of the work to which the tool is in contact, based on a preset modeling diagram of the modeled object. The work posture adjusting method according to (1) or (2).
According to this work posture adjusting method, the accuracy of detecting the position of the work can be improved by bringing the tool into vertical contact with the peripheral surface of the work.

(4) A method for manufacturing a modeled object in which a welded bead is formed around the work whose posture is adjusted by the work attitude adjusting method according to any one of (1) to (3).
According to this method for manufacturing a modeled object, a welded bead can be formed on the peripheral surface of a work positioned with high accuracy to produce a high-quality modeled object.

(5) A support mechanism that supports a columnar workpiece with a circular cross-sectional view, and
A tool for forming a welded bead by melting and solidifying a filler metal,
A movement mechanism for moving the tool and
A controller that controls the movement mechanism and moves the tool along the peripheral surface of the work to form a welded bead in which the filler metal is melted and solidified on the peripheral surface of the work to form a modeled object.
Equipped with
The controller
By controlling the movement mechanism, the tool is brought into contact with the peripheral surface of the work to detect the position at a plurality of circumferential positions in the axial position, which are a plurality of axial positions of the work. death,
Calculate the coordinates of the detected position and
The inclination of the work is calculated from the coordinates of the calculated position,
A device for manufacturing a modeled object that controls the support mechanism based on the calculated inclination of the work and adjusts the posture of the work to a preset posture.
According to this model manufacturing device, when a welded bead is formed on the peripheral surface of a columnar work having a circular cross-sectional view to manufacture a model, the controller supports the work in a highly accurately positioned state. As a result, even if the work is large, it is possible to form a welded bead on the peripheral surface of the work while suppressing an error as much as possible to form a high-quality model. Further, when positioning the work, a tool for forming a welded bead is brought into contact with the work to detect the position, so that it is not necessary to separately provide a sensor for position detection, and the equipment cost can be suppressed.

15 Controller 16 Support mechanism 17 Torch (tool)
19 Welding robot (movement mechanism)
20 Work 25 Welding bead 100 Manufacturing system (manufacturing equipment)
M filler metal R1, R2, R3 circumferential position W modeled object Z1, Z2 axial position

Claims (5)

The tool is moved along the peripheral surface of the columnar workpiece having a circular cross-sectional shape supported by the support mechanism to form a welded bead in which the filler metal is melted and solidified on the peripheral surface of the workpiece to form a modeled object. It is a work posture adjustment method for adjusting the posture of the work at the time of performing.
Position detection processing for detecting the position by bringing the tool into contact with the peripheral surface of the work at a plurality of circumferential positions in the axial position which are a plurality of axial positions of the work.
Coordinate calculation processing to calculate the coordinates of the detected position, and
Inclination calculation processing that calculates the inclination of the work from the coordinates of the calculated position,
A posture adjustment process for adjusting the posture of the work to a preset posture by the support mechanism based on the calculated inclination of the work, and
Work posture adjustment method including. In the position detection process, the formation start position coordinates and the formation end position coordinates, which are the axial position coordinates of the work, of the formation start position and the formation end position of the welded bead are obtained based on the modeling diagram of the modeled object set in advance. The work posture adjusting method according to claim 1, wherein the axial position at which the tool is brought into contact with the work is determined from the formation start position coordinates and the formation end position coordinates. Claim 1 in the position detection process, the tool is moved so that the tool is in vertical contact with the peripheral surface of the work to which the tool is in contact, based on a preset modeling diagram of the modeled object. Alternatively, the work posture adjusting method according to claim 2. A method for manufacturing a modeled object, wherein a welded bead is formed around the work whose posture is adjusted by the work posture adjusting method according to any one of claims 1 to 3. A support mechanism that supports a columnar workpiece with a circular cross-sectional view,
A tool for forming a welded bead by melting and solidifying a filler metal,
A movement mechanism for moving the tool and
A controller that controls the movement mechanism and moves the tool along the peripheral surface of the work to form a welded bead in which the filler metal is melted and solidified on the peripheral surface of the work to form a modeled object.
Equipped with
The controller
By controlling the movement mechanism, the tool is brought into contact with the peripheral surface of the work to detect the position at a plurality of circumferential positions in the axial position, which are a plurality of axial positions of the work. death,
Calculate the coordinates of the detected position and
The inclination of the work is calculated from the coordinates of the calculated position,
A device for manufacturing a modeled object that controls the support mechanism based on the calculated inclination of the work and adjusts the posture of the work to a preset posture.

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