JP7223644B2 - Modeled article manufacturing method and modeled article manufacturing control method - Google Patents

Description

The present invention relates to a method for manufacturing a model, and manufacturing control for manufacturing a model including a laminate in which a plurality of beads formed by melting and solidifying a filler material using an arc are arranged and stacked on a base material. The present invention relates to a method, manufacturing control device, and program.

A welding system that performs multi-layer welding by controlling a robot and a welding machine by a welding control device equipped with a robot controller and an interference check device, wherein the groove shape is measured before welding starts and after welding of a predetermined number of layers. At each end point, the set welding conditions are corrected based on the groove shape data obtained from the groove shape, and whether the work, welding torch, and robot interfere with each other during welding under the corrected welding conditions. Welding systems that perform welding after checking are known (see, for example, U.S. Pat.

JP 2004-268098 A

Even if beads are laminated according to a lamination plan in which the bead lamination height is a target value, the bead lamination height may actually deviate from the target value. In such a case, if the lamination height of the bead is deviated from the target value every time one layer of bead is formed is evaluated, and if it is deviated, the welding conditions are corrected. Processing load becomes heavy.

An object of the present invention is to evaluate whether or not the bead lamination height deviates from the target value each time a bead layer is formed when laminating beads according to a lamination plan in which the bead lamination height is a target value. To reduce the processing load in comparison with the case of correcting welding conditions if there is a deviation.

For this purpose, the present invention provides a step of dividing a plurality of slice data obtained by dividing three-dimensional shape data into a plurality of layers into a plurality of bead data corresponding to a plurality of beads, A step of assigning an order to the data, and a step of laminating beads formed by melting and solidifying the filler material in the assigned order based on the plurality of bead data, and in the step of assigning the order, the plurality of bead data In the step of assigning a continuous order in the stacking direction to a predetermined portion of the and laminating, for the predetermined portion, beads are formed in the order assigned to the predetermined portion, and then the bead stacking height in the predetermined portion To provide a method for manufacturing a modeled article, correcting lamination conditions so that .alpha.

In the step of assigning the order, the next part of the plurality of bead data is assigned a continuous order in the layer direction, and in the step of laminating, the bead is formed for the next part in the order assigned to the next part. You can do

The predetermined portion may be a portion including bead data corresponding to beads arranged in the stacking direction at the end of the modeled object.

The predetermined portion may be a portion including at least two sets of bead data corresponding to beads arranged in the stacking direction.

The present invention also provides a manufacturing control method for a modeled object including a laminate in which a plurality of beads formed by melting and solidifying a filler material using an arc are arranged and stacked on a base material, the method comprising: A step of controlling formation of beads in a stacking direction for a predetermined portion, a step of correcting lamination conditions so that the bead stacking height in the predetermined portion is a target value, and a predetermined portion of a plurality of beads. and controlling the formation of the beads under the corrected lamination conditions for the next portion of the shaped article manufacturing control method.

In the step of controlling the bead formation for the next portion, the bead formation for the next portion may be controlled in an in-layer direction.

The predetermined portion may be a portion including beads arranged in the stacking direction at the end of the modeled object.

The predetermined portion may be a portion including at least two sets of beads arranged in the stacking direction.

Furthermore, the present invention provides a manufacturing control apparatus for a shaped object including a laminate in which a plurality of beads obtained by melting and solidifying a filler material using an arc are arranged and stacked on a base material, wherein the plurality of beads Bead formation control means for controlling formation of beads in the lamination direction for a predetermined portion, and lamination condition correction means for correcting the lamination condition so that the bead lamination height in the predetermined portion becomes a target value. The bead formation control means also provides a modeled product manufacturing control device that controls formation of beads under the lamination conditions corrected by the lamination condition correction means for the portions next to the predetermined portions of the plurality of beads.

Furthermore, the present invention is intended to make a computer function as a manufacturing control apparatus for a modeled product including a laminate in which a plurality of beads formed by melting and solidifying a filler material using an arc are arranged and stacked on a base material. The program includes means for controlling a computer to form beads in a lamination direction for a predetermined portion of a plurality of beads, and lamination conditions such that the lamination height of the beads in the predetermined portion is a target value. Also provided is a program for functioning as a means for correcting and a means for controlling formation of beads under the corrected lamination conditions for a portion next to a predetermined portion of a plurality of beads.

According to the present invention, when laminating beads according to a lamination plan in which the bead lamination height is a target value, it is evaluated whether the bead lamination height deviates from the target value each time one layer of beads is formed. The processing load can be reduced compared to the case of correcting the welding conditions if there is a deviation.

BRIEF DESCRIPTION OF THE DRAWINGS It is the figure which showed the example of a schematic structure of the metal additive manufacturing system in embodiment of this invention. It is a figure which shows the hardware structural example of the control apparatus in embodiment of this invention. It is the figure which showed the lamination|stacking plan of the laminate-molded article at the time of evaluating the thickness and width|variety, and performing feedback whenever forming one layer of bead. It is the figure which showed the lamination plan of the laminate-molded article at the time of applying embodiment of this invention. It is the figure which showed the laminate-molded article in process of shaping at the time of applying embodiment of this invention. FIG. 6 is a graph showing fine adjustment of welding conditions for each bead element in FIG. 5; FIG. 1 is a diagram showing a functional configuration example of a stacking planning device according to an embodiment of the present invention; FIG. It is the figure which showed the functional structural example of the control apparatus in embodiment of this invention. 4 is a flow chart showing an operation example of the stacking planning device according to the embodiment of the present invention; 4 is a flow chart showing an operation example of the control device according to the embodiment of the present invention; 4 is a flow chart showing an operation example of the control device according to the embodiment of the present invention;

BEST MODE FOR CARRYING OUT THE INVENTION Hereinafter, embodiments of the present invention will be described in detail with reference to the accompanying drawings.

[Configuration of metal additive manufacturing system]
FIG. 1 is a diagram showing a schematic configuration example of a metal additive manufacturing system 1 according to the present embodiment.

As illustrated, the metal additive manufacturing system 1 includes a welding robot (manipulator) 10 , a height measuring device 15 , a CAD device 20 , a laminate planning device 30 and a control device 50 . In addition, the stacking planning device 30 writes a control program for controlling the welding robot 10 in a removable recording medium 70 such as a memory card, and the control device 50 can read out the control program written in the recording medium 70. It's like

The welding robot 10 has an arm 11 having a plurality of joints, and operates according to a control program read by the control device 50 to perform welding work. The welding robot 10 also has a welding torch 13 for forming the laminate-molded article 100 at the tip of the arm 11 via the wrist portion 12 . In the case of the metal additive manufacturing system 1 , the welding robot 10 moves the welding torch 13 while melting the mild steel filler material (wire) 14 to manufacture the additive model 100 . Specifically, the welding torch 13 supplies the filler material 14 and generates an arc while flowing a shielding gas to melt and solidify the filler material 14 , thereby forming a plurality of layers of beads 101 on the base material 90 . A laminate-molded article 100 is manufactured by lamination. Here, an arc is used as the heat source for melting the filler metal 14, but laser or plasma may be used. The welding robot 10 also includes a feeding device for feeding the filler material 14, etc., but the description thereof will be omitted.

A height measuring device 15 measures the height of the bead 101 . As a method for measuring the height of the bead 101, any measuring method such as a contact method or a non-contact method may be used. is preferably used. The height measuring device 15 measures the height of the bead 101 each time one layer of the bead 101 is formed.

The CAD device 20 has a function of designing a modeled object using a computer and holding three-dimensional data obtained by the design (hereinafter referred to as “three-dimensional CAD data”).

The stacking planning device 30 determines the trajectory of the welding torch 13 based on the three-dimensional CAD data held by the CAD device 20 and determines the welding conditions when the welding robot 10 performs welding. A control program for controlling the welding robot 10 to form the bead 101 along the determined trajectory under the determined welding conditions is then generated, and this control program is output to the recording medium 70 .

The control device 50 reads the control program from the recording medium 70 and holds it. By operating this control program, the welding robot 10 is controlled to form the bead 101 under the welding conditions planned by the lamination planning device 30 along the trajectory planned by the lamination planning device 30 . In the present embodiment, a control device 50 is provided as an example of a model manufacturing control device.

[Hardware configuration of control device]
FIG. 2 is a diagram showing a hardware configuration example of the control device 50. As shown in FIG.

As shown in the figure, the control device 50 is realized by, for example, a general-purpose PC (Personal Computer) or the like, and includes a CPU 51 as computing means, a main memory 52 and a magnetic disk device (HDD: Hard Disk Drive) 53 as storage means. Prepare. Here, the CPU 51 executes various programs such as an OS (Operating System) and application software to realize each function of the control device 50 . The main memory 52 is a storage area for storing various programs and data used for executing them, and the HDD 53 is a storage area for storing input data to various programs and output data from various programs.

The control device 50 also provides a communication I/F 54 for communicating with the outside, a display mechanism 55 including a video memory, a display, etc., an input device 56 such as a keyboard and a mouse, and a recording medium 70 for data transmission. and a driver 57 for reading and writing. Note that FIG. 2 merely illustrates a hardware configuration when the control device 50 is realized by a computer system, and the control device 50 is not limited to the illustrated configuration.

Moreover, the hardware configuration shown in FIG. 2 can also be understood as the hardware configuration of the stacking planning device 30 . However, when describing the lamination planning device 30, the CPU 51, main memory 52, magnetic disk device 53, communication I/F 54, display mechanism 55, input device 56, and driver 57 in FIG. A disk device 33 , a communication I/F 34 , a display mechanism 35 , an input device 36 and a driver 37 are used.

[Overview of the present embodiment]
In the metal additive manufacturing system 1 having such a configuration, if the thickness and width of the bead 101 are evaluated and fed back each time one layer of bead 101 is formed, the control is frequently performed, so the processing is slow. It will be heavy and quality control will be complicated.

Therefore, in the present embodiment, trajectory data generated from layer shape data obtained by dividing three-dimensional CAD data into a plurality of layers is divided into partial trajectory data corresponding to bead elements. As for the partial trajectory data corresponding to the bead elements adjacent to the end of the laminate-molded article 100, the partial trajectory data corresponding to the bead elements arranged in the stacking direction (height direction) are treated as one set.

That is, when the stacking order is set, the order is set such that the stacking is preferentially performed for that set. Next, the order is set for parts other than the set.

After that, when laminating and manufacturing is actually performed, lamination of the bead elements is started from that set, and the welding conditions are finely adjusted for each bead element so that the total height deviation in one set is below the allowable value. Then, as soon as a welding condition is found in which the total height deviation in one set is below the allowable value, the lamination is developed laterally.

This will be described below using a specific example. Here, as the laminate-molded article 100, an article having a trapezoidal shape when viewed from a certain direction is taken as an example. A plurality of layers are distinguished by an index i, and the index i takes a value from 1 to 5. In addition, a plurality of bead elements in a layer are distinguished by an index j. In layers with an index i of 1 or 2, the index j takes a value from 1 to 7, and in a layer with an index i of 3 or 4, the index j is 1. to 6, and in the layer where the index i is 5, the index j takes a value from 1 to 5. Further, hereinafter, the bead element of index j in the layer of index i or partial trajectory data corresponding thereto is denoted by B(i, j), and the height of bead element B(i, j) is denoted by H(i, j).

FIG. 3 is a diagram showing a stacking plan for the laminate-molded article 100 when the thickness and width of the bead 101 are evaluated and fed back each time one layer of the bead 101 is formed. In this figure, the dashed line indicates the shape of the laminate 100, and the buildup is planned to encompass this shape with a plurality of bead elements. In this case, when setting the lamination order, the order is set for the partial trajectory data corresponding to the bead elements for each layer. In the figure, the order is set from left to right, as indicated by the circled numbers. That is, for the first layer, the order is set for B(1,1), . . . , B(1,7) in this order. For the second layer, the order is set for B(2,1), . . . , B(2,7) in this order. For the third layer, the order is set for B(3,1), . . . , B(3,6) in this order. For the fourth layer, the order is set for B(4,1), . . . , B(4,6) in this order. For the fifth layer, the order is set for B(5, 1), . . . , B(5, 5) in this order.

After that, when lamination-molding is actually performed, bead elements are formed from the layer whose index i is 1 according to the order within the layer, as indicated by the arrow in FIG. Then, as soon as the bead elements of each layer are formed, the welding conditions are finely adjusted to form the bead elements of the next index layer.

FIG. 4 is a diagram showing a lamination plan for the laminate-molded article 100 to which the present embodiment is applied. Also in this figure, the dashed line indicates the shape of the laminate-molded article 100, and the stacking plan is carried out so that this shape is encompassed by a plurality of bead elements. In this case, when the stacking order is set, the order is set such that a predetermined number of partial trajectory data sets close to the end of the laminate-molded article 100 are preferentially stacked. In the figure, the predetermined number is "2", and the leftmost two sets are ordered from bottom to top as indicated by circled numbers. That is, for the set 111, the order is set for B(1,1), . . . , B(5,1) in this order. For the set 112, the order is set for B(1,2), . . . , B(5,2) in this order. At this time, the sets 111 and 112 are examples of predetermined portions including bead data corresponding to beads arranged in the stacking direction at the ends of the modeled object. However, the sets 111 and 112 may not be provided at the ends of the modeled object. At this time, the sets 111 and 112 are examples of predetermined portions of a plurality of bead data. Also, the number of sets is not limited to two, and may be at least two. Next, the order is set for parts other than the sets 111 and 112 as well. In addition, since the setting method of the order at this time may be arbitrary, the specific order is not shown in the figure. At this time, the portions after sets 111 and 112 are an example of the next portion of the predetermined portion.

FIG. 5 is a diagram showing the laminate-molded article 100 being molded to which the present embodiment is applied. In this case, when actually performing layered manufacturing, first, bead elements are layered according to the set order for the set 111 as indicated by the arrow. Here, as shown by ΔH(1) in the figure, it is assumed that the deviation of the actual lamination height in the set 111 from the height of the laminate-molded article 100 exceeds the allowable value. In this case, the welding conditions are fine-tuned for each bead element, and for the set 112, as indicated by the arrow, the bead elements are stacked according to the set order with the fine-tuned welding conditions. At this time, the sets 111 and 112 are examples of predetermined portions including beads arranged in the stacking direction at the ends of the modeled object. However, the sets 111 and 112 may not be provided at the ends of the modeled object. At this time, the sets 111 and 112 are examples of predetermined portions of a plurality of beads. Also, the number of sets is not limited to two, and may be at least two. Here, as the height of the set 112 is shown to be almost the same as the height of the laminate-molded article 100 in the figure, the deviation of the actual laminate height in the set 112 from the height of the laminate-molded article 100 is less than the allowable value. Suppose it became In this case, bead elements are formed under the finely adjusted welding conditions according to the set order for portions other than the sets 111 and 112 . Although FIG. 4 does not show a specific order for parts other than the sets 111 and 112, the arrows indicate that the bead elements are formed from left to right as an example here. At this time, the portions other than the sets 111 and 112 are examples of portions following the predetermined portion of the plurality of beads.

FIG. 6 is a graph showing fine adjustment of welding conditions for each bead element in FIG. The vertical axis indicates the height deviation of each layer, that is, how much the actual lamination height deviates from the target value for each layer. '0' indicates that the actual stack height matches the target value, '+' indicates that the actual stack height is higher than the target value, and '-' indicates that the actual stack height is higher than the target value. indicates that it is lower than Also, the horizontal axis indicates the number of layers. Here, the number of layers is set to "5" in accordance with the examples of FIGS. In this graph, the actual lamination heights of the first and second layers are higher than the target values, and the actual lamination heights of the third to fifth layers are lower than the target values. That is, this graph shows that there is no need to fine-tune the welding conditions so that the actual stacking height approaches the target value for all five layers, and the actual stacking height of the five layers as a whole is the target value. This indicates that the welding conditions for each layer should be finely adjusted so that the height of the layer approaches the height of .

In the above description, the laminate-molded article 100 manufactured by laminating five layers of beads 101 is taken as an example, but the laminate-molded article 100 is not limited to this. Generalizing, the laminate-molded article 100 may be manufactured by laminating N layers of beads 101 . In addition, the beads 101 of the first and second layers are formed of seven bead elements, and the beads 101 of the third and fourth layers are formed of six bead elements, thereby forming the beads 101 of the fifth layer. The bead 101 is exemplified by laminating five bead elements, but the present invention is not limited to this. As a generalization, the i-th bead 101 may be laminated by forming M(i) bead elements.

In the above description, the portion obtained by dividing the bead 101 is referred to as a "bead element" for the sake of convenience to distinguish it from the bead 101, but the portion obtained by dividing the bead 101 is referred to as a "bead". good too.

[Functional configuration of the present embodiment]
(Functional configuration of lamination planning device)
FIG. 7 is a diagram showing a functional configuration example of the stacking planning device 30 in this embodiment. As illustrated, the stacking planning apparatus 30 in the present embodiment includes a CAD data acquisition unit 41, a CAD data dividing unit 42, a track data generating unit 43, a track data dividing unit 44, and a stacking order setting unit 45. , a welding condition generation unit 46 , a control program generation unit 47 , and a control program output unit 48 .

The CAD data acquisition unit 41 acquires three-dimensional CAD data representing the three-dimensional shape of the laminate-molded article 100 from the CAD device 20 . In this embodiment, three-dimensional CAD data is used as an example of three-dimensional shape data.

The CAD data division unit 42 divides (slices) the three-dimensional CAD data acquired by the CAD data acquisition unit 41 into a plurality of layers, thereby generating a plurality of layer shape data representing the shape of each layer. At that time, the CAD data division unit 42 may convert the three-dimensional CAD data into an internal format that facilitates division into a plurality of layers. In this embodiment, a plurality of layer shape data is used as an example of a plurality of slice data obtained by dividing the three-dimensional shape data into a plurality of layers.

The trajectory data generation unit 43 sets the start point and the end point of the bead 101 for each layer with respect to the plurality of layer shape data generated by the CAD data division unit 42, and determines the formation path of the bead 101 from the start point to the end point. Generate trajectory data representing a trajectory.

The trajectory data dividing unit 44 divides the trajectory data generated by the trajectory data generating unit 43 into portions corresponding to a plurality of bead elements, thereby generating a plurality of partial trajectory data. In the present embodiment, a plurality of partial trajectory data are used as an example of a plurality of bead data respectively corresponding to a plurality of beads.

The stacking order setting unit 45 sets the stacking order for the plurality of partial track data generated by the track data dividing unit 44 . At that time, among the plurality of partial trajectory data, for a set of partial trajectory data corresponding to a set of bead elements arranged in the stacking direction (height direction) at a position close to the end of the laminate-molded article 100, Set the order from the layer above. On the other hand, for other partial trajectory data, the order is set for each layer.

The welding condition generating unit 46 performs welding for each layer based on the layer shape data generated by the CAD data dividing unit 42, the partial track data generated by the track data dividing unit 44, and the stacking order set by the stacking order setting unit 45. create welding conditions that are the conditions for forming the bead elements of Here, the welding conditions are, for example, welding current, arc voltage, welding speed and the like. The welding conditions generated by the welding condition generation unit 46 may be finely adjusted by the control device 50 thereafter, so they are referred to as "initial welding conditions" in the sense of initial welding conditions.

The control program generating unit 47 forms bead elements corresponding to the partial track data generated by the track data dividing unit 44 under the welding conditions generated by the welding condition generating unit 46 according to the layering order set by the layering order setting unit 45. Thus, a control program for controlling the welding robot 10 is generated.

The control program output unit 48 outputs the control program generated by the control program generation unit 47 to the recording medium 70 .

(Functional configuration of control device)
FIG. 8 is a diagram showing a functional configuration example of the control device 50 in this embodiment. As illustrated, the control device 50 in this embodiment includes a control program acquisition section 61 , a control program storage section 62 , a height data reception section 63 and a control program execution section 64 .

The control program acquisition unit 61 acquires the control program recorded on the recording medium 70 .

The control program storage unit 62 stores the control program acquired by the control program acquisition unit 61 .

The height data receiving unit 63 receives height data indicating the measured height from the height measuring device 15 that measures the height of each layer of bead element formed.

The control program execution unit 64 reads and executes the control program stored in the control program storage unit 62 . Thereby, the control program execution unit 64 controls the welding robot 10 to form a plurality of bead elements according to the stacking order set by the stacking order setting unit 45 . That is, for a set of bead elements arranged in the stacking direction (height direction) at a position close to the end of the laminate-molded article 100, welding is performed so that the bead elements are stacked from the lower layer to the upper layer under trial welding conditions. Control the robot 10 . Here, for the first set of bead elements, control is performed so that the bead elements are stacked using the initial welding conditions as the trial welding conditions. This function of the control program execution unit 64 is an example of bead formation control means for controlling formation of beads in the stacking direction for predetermined portions of a plurality of beads. Then, if the deviation of the actual lamination height of the set of bead elements from the target value exceeds the allowable value, the adjusted welding conditions obtained by adjusting the welding conditions are newly set as the trial welding conditions. The welding condition is an example of the lamination condition, and this function of the control program execution unit 64 is an example of lamination condition correction means for correcting the lamination condition so that the bead lamination height at a predetermined portion becomes the target value. be. After that, the control program execution unit 64 controls the welding robot 10 to laminate the bead elements from the lower layer to the upper layer under the trial welding conditions for the next set of bead elements. On the other hand, if the deviation of the actual lamination height of the set of bead elements from the target value does not exceed the allowable value, the welding robot 10 is configured to form subsequent bead elements using the current trial welding conditions as the positive welding conditions. to control. This function of the control program execution unit 64 is an example of bead formation control means for controlling formation of beads under the lamination conditions corrected by the lamination condition correction means for the portions next to the predetermined portions of the plurality of beads. is.

[Operation of this embodiment]
(Operation of lamination planning device)
FIG. 9 is a flow chart showing an operation example of the stacking planning device 30 in this embodiment.

In the stacking planning device 30, first, the CAD data acquisition unit 41 acquires three-dimensional CAD data from the CAD device 20 (step 301).

Next, the CAD data division unit 42 divides the three-dimensional CAD data acquired in step 301 into a plurality of layers to generate layer shape data (step 302).

Next, the trajectory data generator 43 sets the start point and end point of the bead 101 to the layer shape data generated in step 302 to generate trajectory data (step 303).

Next, the trajectory data division unit 44 divides the trajectory data generated in step 303 into portions corresponding to a plurality of bead elements to generate a plurality of partial trajectory data (step 304).

Next, the stacking order setting unit 45 sets the stacking order for the plurality of partial trajectory data generated in step 304 (step 305). For example, for two sets of partial trajectory data corresponding to two sets of bead elements aligned in the stacking direction (height direction) at a position close to the edge of the laminate 100, The order is set for each layer, and for other partial trajectory data, the order is set in the direction within the layer.

In addition, the welding condition generation unit 46 generates a bead for each layer based on the layer shape data generated in step 302, the plurality of partial trajectory data generated in step 304, and the stacking order set in step 305. Welding conditions, which are the conditions for forming the elements, are generated (step 306). The welding conditions generated here are the initial welding conditions.

Next, the control program generator 47 controls the welding robot 10 based on the plurality of partial trajectory data generated in step 304, the stacking order set in step 305, and the welding conditions generated in step 306. A control program is generated (step 307). Specifically, a control program is generated for controlling the welding robot 10 so as to weld a plurality of bead elements respectively corresponding to a plurality of partial trajectory data in the set stacking order under the generated welding conditions.

Finally, the control program output unit 48 outputs the control program generated in step 307 to the recording medium 70 (step 308).

(Operation of control device)
In the control device 50 , first, the control program acquisition section 61 acquires the control program from the recording medium 70 and stores it in the control program storage section 62 . In this state, when the laminate-molded article 100 is actually manufactured using the welding robot 10, the height data receiving unit 63 receives from the height measuring device 15 the height indicating the height of the bead element for each layer. While receiving the data, the control program execution unit 64 reads the control program stored in the control program storage unit 62 and executes it.

10-1 and 10-2 are flow charts showing an operation example of the control program execution unit 64. FIG. Also in this flowchart, as described above, the layer index is i, the number of layers is N, the index of the bead element in the layer is j, and the number of bead elements in the layer with index i is M(i ). Let m be the minimum value of M(i) when the index i is varied from 1 to N. Further, as described above, the bead element with index j in the layer with index i is B(i,j), and the height of bead element B(i,j) is H(i,j). Furthermore, let Ht be the target height of a set of bead elements.

In addition, the above assumes that when the deviation of the actual stack height from the target value in one set falls below the tolerance, the bead elements are formed in any order within the layer for subsequent portions. . However, for ease of explanation, it is assumed hereafter that the bead elements are formed from left to right within the layers.

As shown in FIG. 10-1, the control program execution unit 64 first sets the index j of the bead element to 1 (step 501). In other words, focus on the first set of bead elements. Then, the initial welding conditions for each layer generated in step 306 of FIG. 9 and included in the control program are set as trial welding conditions (step 502).

Next, the control program execution unit 64 sets the layer index i to 1 (step 503). That is, look at the first layer in the first set of bead elements.

Next, the control program execution unit 64 forms the i-th bead element under trial welding conditions while incrementing the index i from 1 to N by 1, thereby forming the i-th bead element in the set of the j-th bead element. Processing is performed to form bead elements from the bead element to the N-th bead element under trial welding conditions. That is, the control program execution unit 64 controls the welding robot 10 to form the bead element B(i, j) under the trial welding conditions (step 504). Then, the control program executing section 64 acquires the height H(i, j) of the bead element B(i, j) from the height data receiving section 63 (step 505). The control program execution unit 64 also adds 1 to the index i (step 506) and determines whether the index i exceeds N (step 507). If the control program execution unit 64 determines that the index i does not exceed N, there are still bead elements to be formed, so the process returns to step 504 . On the other hand, if it is determined that the index i has exceeded N, then the process proceeds to step 508 because bead elements up to the N-th layer have been formed.

After that, the control program execution unit 64 subtracts the target height Ht from the sum of the heights H(i,j) obtained in step 505 while incrementing the index i from 1 to N by one to obtain j Determine the height deviation ΔH(j) in the set of bead elements (step 508). Then, it is determined whether or not the height deviation ΔH(j) exceeds the allowable value ε (step 509). If the control program execution unit 64 determines that the height deviation ΔH(j) exceeds the allowable value ε, the process proceeds to step 510 . On the other hand, if it is determined that the height deviation ΔH(j) does not exceed the allowable value ε, the formation of the bead element under the trial welding conditions at this time can be laterally expanded, so the process proceeds to FIG. 10-2.

If it is determined in step 509 that the height deviation ΔH(j) exceeds the allowable value ε, the control program execution unit 64 adds 1 to the index j (step 510) and determines whether the index j exceeds m. is determined (step 511). If control program execution unit 64 determines that index j does not exceed m, then there is still a set of bead elements that can be formed for fine adjustment of trial welding conditions, and the process proceeds to step 512 . On the other hand, if it is determined that the index j exceeds m, then there is no set of bead elements that can be formed for fine tuning the trial welding conditions, and the process ends.

If it is determined in step 511 that the index j does not exceed m, the control program execution unit 64 generates adjusted welding conditions obtained by fine-tuning the trial welding conditions, sets them as the trial welding conditions (step 512), and starts the process. Return to step 503 .

Further, if it is determined in step 509 that the height deviation ΔH(j) does not exceed the allowable value ε, the control program execution unit 64 changes the value of the index j at this time to the variable It is set to k (step 551), and the trial welding conditions at this time are set as normal welding conditions (step 552).

Next, the control program execution unit 64 sets the layer index i to 1 (step 553). In other words, focus on the first layer.

Next, the control program execution unit 64 sets the bead element index j to (k+1) (step 554). That is, focus on the (k+1)-th bead element in the first layer.

Next, the control program execution unit 64 forms the j-th bead element under normal welding conditions while incrementing the index j from (k+1) to M(i) by 1, thereby increasing the index j from the (k+1)-th bead element to M (i) A process of forming under normal welding conditions is performed up to the i-th bead element. That is, the control program execution unit 64 controls the welding robot 10 to form the bead element B(i, j) under normal welding conditions (step 555). The control program execution unit 64 also adds 1 to the index j (step 556) and determines whether the index j exceeds M(i) (step 557). If the control program execution unit 64 determines that the index j does not exceed M(i), there are still bead elements to be formed, so the process returns to step 555 . On the other hand, if it is determined that the index j has exceeded M(i), then the process proceeds to step 558 since the M(i)th bead element has been formed.

After that, the control program execution unit 64 adds 1 to the index i (step 558) and determines whether the index i exceeds N (step 559). If the control program execution unit 64 determines that the index i does not exceed N, there are still layers to be formed, so the process returns to step 554 . On the other hand, if it is determined that the index i has exceeded N, the processing ends because up to the Nth layer has been formed.

In the present embodiment, the number of sets of bead elements for forming bead elements in the lamination direction is set in advance by the lamination planning device 30 in order to find the welding conditions for lateral expansion, and the control device 50 actually sets the number of bead element sets. Although it was made to change while performing lamination molding, it is not limited to this. The number of sets of such bead elements may not be set in advance by the lamination planning device 30, but may be determined by the control device 50 while performing the actual lamination manufacturing.

[Effects of this embodiment]
As described above, in the present embodiment, after forming bead elements in the stacking direction for a set of a plurality of bead elements close to the end, Then, the welding conditions were corrected, and the bead elements were formed under the corrected welding conditions for the portions after that set. This makes it possible to reduce the processing load when laminating the bead elements according to a lamination plan in which the lamination height of the bead elements is a target value.

DESCRIPTION OF SYMBOLS 1... Metal additive manufacturing system, 10... Welding robot, 20... CAD apparatus, 30... Lamination planning apparatus, 41... CAD data acquisition part, 42... CAD data division part, 43... Trajectory data generation part, 44... Trajectory data division part , 45... Lamination order setting unit 46... Welding condition generation unit 47... Control program generation unit 48... Control program output unit 50... Control device 61... Control program acquisition unit 62... Control program storage unit 63... Height data receiving unit 64 Control program execution unit 70 Recording medium

Claims (6)

a step of dividing a plurality of slice data obtained by dividing the three-dimensional shape data into a plurality of layers into a plurality of bead data respectively corresponding to the plurality of beads;
assigning an order to the plurality of bead data;
Laminating beads formed by melting and solidifying a filler material in an assigned order based on the plurality of bead data;
In the step of allocating the order, allocating a continuous order in the stacking direction to a predetermined portion of the plurality of bead data;
In the step of stacking, for the predetermined portion, beads are formed in the order assigned to the predetermined portion, and then the stacking conditions are adjusted so that the bead stack height in the predetermined portion is a target value. A method for manufacturing a modeled object, comprising: correcting the lamination condition, and forming a bead for a portion next to the predetermined portion under the corrected lamination condition. In the step of assigning the order, assigning the next part of the plurality of bead data successive orders in an intra-layer direction;
2. The method according to claim 1, wherein in said layering step, beads are formed for said next portion in the order assigned to said next portion. 2. The method of manufacturing a modeled article according to claim 1, wherein the predetermined portion is a portion including bead data corresponding to beads arranged in the stacking direction at the end of the modeled article. 2. The method of manufacturing a model according to claim 1, wherein the predetermined portion is a portion including at least two sets of bead data corresponding to beads arranged in the stacking direction. A manufacturing control method for a shaped object including a laminate in which a plurality of beads formed by melting and solidifying a filler material using an arc are arranged and stacked on a base material,
a step of controlling formation of beads in a stacking direction for predetermined portions of the plurality of beads;
a step of correcting the lamination conditions so that the lamination height of the beads in the predetermined portion becomes a target value;
a step of controlling to form beads under the corrected lamination conditions for a portion subsequent to the predetermined portion of the plurality of beads;
including
A manufacturing control method for a model, wherein in the step of controlling formation of beads for the next portion, control is performed so that beads are formed in an in-layer direction for the next portion. A manufacturing control method for a shaped object including a laminate in which a plurality of beads formed by melting and solidifying a filler material using an arc are arranged and stacked on a base material,
a step of controlling formation of beads in a stacking direction for predetermined portions of the plurality of beads;
a step of correcting the lamination conditions so that the lamination height of the beads in the predetermined portion becomes a target value;
a step of controlling to form beads under the corrected lamination conditions for a portion subsequent to the predetermined portion of the plurality of beads;
including
A manufacturing control method for a model, wherein the predetermined portion is a portion including at least two sets of beads arranged in a stacking direction.

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