JP7232721B2 - Modeled article manufacturing method, modeled article manufacturing control method, modeled article manufacturing control device, and program - Google Patents

Description

The present invention relates to a method for manufacturing a model, which includes a laminated body in which a plurality of beads formed by melting and solidifying a filler material using an arc is laminated based on three-dimensional shape data, and the model. The present invention relates to a manufacturing control method, a manufacturing control device, and a program.

The cross-section of each layer of a three-dimensional model formed by deposition along a given lamination path of the melt is modeled by an ellipse, and an actual measurement database is created that represents the relationship between specific parameters representing the ellipse model and the forming conditions. Then, for each control point determined for the target shape, the molding conditions are derived so that the difference between the given target shape and the predicted shape predicted using the elliptical model by referring to the actual measurement database is less than or equal to a given allowable value. A computer-aided manufacturing method for three-dimensional modeling is known (see, for example, US Pat.

JP 2018-27558 A

Defects are likely to occur where the arc is turned on or off during bead formation. Therefore, if a configuration is adopted in which the start and end points of the bead are set within the final modeled product, defects caused by turning on or off the arc will have a greater effect on the final modeled product.

It is an object of the present invention to reduce the impact of defects caused by turning the arc on or off on the final build.

Based on this object, the present invention provides a manufacturing method for manufacturing a modeled product, which includes a laminated body in which a plurality of beads formed by melting and solidifying a filler material using an arc is laminated based on three-dimensional shape data. A method comprising: determining the start point and end point of a bead in each layer from slice data obtained by dividing three-dimensional shape data into a plurality of layers; A process of correcting the slice data so as to extend to the start point and the new end point respectively, and a process of forming a bead from the new start point toward the new end point based on the corrected slice data, thereby manufacturing the modeled object. and to provide a method for manufacturing a modeled article.

Here, in the correcting step, the slice data may be corrected so that the start point and the end point are respectively extended to a new start point and a new end point on the intersection line with respect to the bead formation direction.

In addition, in the modifying step, the slice data may be modified so as to extend the start point and end point to a new start point and new end point outside the modeled object, respectively. At that time, the method for manufacturing the shaped article further includes a step of cutting extending portions from the start and end points of all the beads to new start and new end points after all the beads are formed in the manufacturing process. can be anything.

Further, the modifying step may modify the slice data to extend the start point and end point respectively to a new start point and new end point inside the feature. At that time, in the manufacturing process, each time the bead is laminated, the extending portion from the start point and the end point of the laminated bead to the new start point and the new end point may be cut.

Furthermore, in the manufacturing process, the stretch from the start and end points of the bead to the new start and new end points may be formed at a slower speed than the non-stretch portions of the bead.

In addition, the present invention provides a manufacturing control method for a modeled product, which controls the manufacturing of a modeled product including a laminate in which a plurality of beads formed by melting and solidifying a filler material using an arc is superimposed, based on three-dimensional shape data. A step of acquiring the start point and end point of the bead in each layer of slice data obtained by dividing the three-dimensional shape data into a plurality of layers; Information for manufacturing a modeled object by correcting the slice data so as to extend each to a new end point, and forming a bead from the new start point to the new end point based on the corrected slice data. Also provided is a manufacturing control method for a modeled object, including the step of outputting the .

Further, the present invention provides a model manufacturing control device that controls the production of a model including a laminate in which a plurality of beads formed by melting and solidifying a filler material using an arc is stacked based on three-dimensional shape data. Acquisition means for acquiring the start point and end point of the bead in each layer of slice data obtained by dividing the three-dimensional shape data into a plurality of layers, and a new start point located outside the modeled object for the start point and end point and a modification means for modifying the slice data so as to extend to the new end point, respectively, and forming a bead from the new start point toward the new end point based on the modified slice data to manufacture the modeled object. and an output means for outputting the information of .

Furthermore, the present invention provides manufacturing control of a modeled object, which includes a laminated body in which a plurality of beads formed by melting and solidifying a filler material using an arc are stacked based on three-dimensional shape data. A program for causing a computer to function as an apparatus, the computer comprising: acquisition means for acquiring the start point and end point of a bead in each layer of slice data obtained by dividing the three-dimensional shape data into a plurality of layers; Modifying means for modifying the slice data so as to extend the end point to a new start point and a new end point located outside the modeled object; and based on the modified slice data, from the new start point to the new end point. Also provided is a program for functioning as output means for outputting information for manufacturing a modeled article by forming a bead.

The present invention reduces the impact of defects caused by turning the arc on or off on the final build.

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 lamination|stacking planning apparatus in embodiment of this invention. 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 a first operation example of a control program execution unit according to the embodiment of the present invention; 9 is a flow chart showing a second operation example of the control program execution unit according to the embodiment of the present invention; It is the figure which showed an example of three-dimensional CAD data. (a) is a diagram showing an example of layer shape data, and (b) is a diagram showing an example of layer shape data of a first layer. (a) is a diagram showing an example of trajectory data, and (b) is a diagram showing an example of first-layer trajectory data. (a) is a diagram showing an example of corrected trajectory data, and (b) is a diagram showing an example of first-layer corrected trajectory data. (a) to (d) are diagrams showing a first example of a manufacturing process of a layered product. (a) to (f) are diagrams showing a second example of a manufacturing process of a layered product.

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 10 , a cutting robot 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 and the cutting robot 15 in a removable recording medium 70 such as a memory card, and the control device 50 writes the control program written in the recording medium 70. It can be read out.

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 feeds the filler material 14 and generates an arc while flowing a shielding gas to melt and solidify the filler material 14 , forming an n-layer bead 101 ( The first-layer bead 101(1) to the n-th layer bead 101(n)) are stacked to manufacture the laminate-molded article 100. FIG. 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.

The cutting robot 15 includes an arm 16 having a plurality of joints, and operates according to a control program read by the control device 50 to perform cutting work. The cutting robot 15 also has a metalworking tool 18 such as an end mill or grinding wheel for cutting a part of the bead at the tip of the arm 16 via the wrist portion 17 . The cutting robot 15 removes unnecessary portions from the n-layer beads 101 (first layer bead 101(1) to n-th layer bead 101(n)) stacked on the base material 90 using the metal working tool 18. By cutting, the laminate-molded article 100 is completed.

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 CAD data held by the CAD device 20 and determines the welding conditions when the welding robot 10 performs welding. Then, a control program is generated for controlling the welding robot 10 so as to form a bead under the determined welding conditions along the determined trajectory. Also, a control program is generated for further controlling the cutting robot 15 so as to cut a part of the formed bead. Then, this control program is output to the recording medium 70 . In this embodiment, a stacking planning device 30 is provided as an example of a production control device for a modeled object.

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 a bead under the welding conditions planned by the lamination planning device 30 along the trajectory planned by the lamination planning device 30 . Also, the cutting robot 15 is controlled to cut a part of the bead as planned by the lamination planning device 30 .

[Hardware configuration of lamination planning device]
FIG. 2 is a diagram showing a hardware configuration example of the stacking planning device 30. As shown in FIG.

As illustrated, the stacking planning apparatus 30 is realized by, for example, a general-purpose PC (Personal Computer) or the like, and includes a CPU 31 as computing means, a main memory 32 and a magnetic disk device (HDD: Hard Disk Drive) 33 as storage means. and Here, the CPU 31 executes various programs such as an OS (Operating System) and application software to realize each function of the stacking planning device 30 . The main memory 32 is a storage area for storing various programs and data used for executing them, and the HDD 33 is a storage area for storing input data to various programs and output data from various programs.

The stacking planning device 30 also has a communication I/F 34 for communicating with the outside, a display mechanism 35 including a video memory, a display, etc., an input device 36 such as a keyboard and a mouse, and a recording medium 70. and a driver 37 for reading and writing data. It should be noted that FIG. 2 merely illustrates a hardware configuration when the stacking planning device 30 is realized by a computer system, and the stacking planning device 30 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 control device 50 . However, when describing the control device 50, the CPU 31, the main memory 32, the magnetic disk device 33, the communication I/F 34, the display mechanism 35, the input device 36, and the driver 37 in FIG. A device 53 , a communication I/F 54 , a display mechanism 55 , an input device 56 and a driver 57 are used.

[Overview of the present embodiment]
In the metal additive manufacturing system 1 having such a configuration, the arc is turned on or off when creating the laminate-molded article 100 in which a plurality of beads are formed by melting and solidifying the filler material 14 using an arc. Defects are likely to occur at certain points. That is, defects are likely to occur at the start and end points of the bead. Therefore, in the present embodiment, the start point and the end point of the bead are extended to a new start point and a new end point located away from the laminate-molded article 100, respectively, and a defect occurs at the point where the arc is turned on or off. However, the effect of the defect on the laminate-molded article 100 is reduced.

[Functional configuration of lamination planning device]
FIG. 3 is a diagram showing a functional configuration example of the stacking planning device 30 in this embodiment. As illustrated, the lamination planning apparatus 30 in the present embodiment includes a CAD data acquisition unit 41, a CAD data division unit 42, a trajectory data generation unit 43, a welding condition generation unit 44, and a trajectory data correction unit 45. , a cutting information generation unit 46 , a control program generation unit 47 , and a control program output unit 48 .

The CAD data acquisition unit 41 acquires the three-dimensional CAD data D3d of the modeled object from which the layered product 100 is based, 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 D3d acquired by the CAD data acquisition unit 41 into layer shape data Ds (first layer Data for n layers including shape data Ds(1) to n-th layer shape data Ds(n)) are generated. At that time, the CAD data division unit 42 may convert the three-dimensional CAD data D3d into an internal format that facilitates division into a plurality of layers. In this embodiment, layer shape data Ds is used as an example of slice data.

The trajectory data generator 43 sets the start point and end point of the bead for each layer in the layer shape data Ds generated by the CAD data division unit 42, and indicates the trajectory that is the bead formation path from the start point to the end point. Trajectory data Dt (data for n layers including the trajectory data Dt(1) of the first layer to the trajectory data Dt(n) of the n-th layer) are generated. In the present embodiment, the trajectory data generation unit 43 is provided as an example of acquisition means for acquiring the start point and end point of the bead in each layer of slice data.

The welding condition generator 44 sets the welding condition Dco, which is the condition for forming a bead, based on the layer shape data Ds generated by the CAD data divider 42 and the trajectory data Dt generated by the trajectory data generator 43. Generate. Here, the welding conditions are, for example, welding current, arc voltage, welding speed and the like. Also, the welding condition generating unit 44 changes the welding condition Dco based on corrected trajectory data Dt' generated by the trajectory data correcting unit 45, which will be described later. Specifically, the welding speed of the extended portion from the start point and end point of the bead to the new start point and new end point is made lower than the welding speed of the portion other than the extended portion of the bead. By forming the stretched portion of the bead at a slower speed than the other portions, the bead is slightly overfilled in the stretched portion, making defects less likely to occur where the arc is turned on or off.

The trajectory data correction unit 45 corrects the trajectory data Dt generated by the trajectory data generation unit 43 so as to extend the start point and end point of the bead set in the trajectory data Dt to new start points and end points for each layer. Thus, corrected trajectory data Dt' (data for n layers including first layer corrected trajectory data Dt'(1) to n-th layer corrected trajectory data Dt'(n)) is generated.

Here, the new start point and end point are such that even if a defect occurs due to the arc being turned on or off, the effect of the defect on the laminate-molded article 100 (for example, the effect on its appearance and functional value) is small. position. An example of a position where the effect of the defect on the laminate-molded article 100 is small is a position in a different direction from the formation path of the bead with reference to the start point and end point of the bead. Specifically, it is good to set it as the position which deviated from the laminate-molded article 100. FIG. By doing so, the occurrence of defects inside the laminate-molded article 100 can be suppressed.

As the coordinates of the position away from the laminate-molded article 100, for example, a vector in a direction intersecting the formation direction of the bead is set, and the x Coordinates obtained by adding double (x is a positive number) may be adopted. In other words, the points on the crossing line with respect to the bead forming direction should be set as the new start point and the new end point.

In addition, one of the new start point and the new end point may be provided outside the layered product 100 and the other may be provided inside the layered product 100, or both may be provided outside the layered product 100. However, both may be provided inside the laminate-molded article 100 .

The instruction information as to which direction the new start point and the new end point are provided with respect to the formation direction of the bead and whether the new start point and the new end point are provided outside or inside the laminate-molded article 100 is , should be preset by the user. Moreover, this instruction information may be set for each type of shape of the laminate-molded article 100 , or may be set for each laminate-molded article 100 .

The trajectory data correction unit 45 extends the start point and end point of the bead set in the trajectory data Dt to new start points and end points, respectively, thereby correcting the layer shape data Ds. In this sense, the trajectory data correction unit 45 can be said to be an example of correction means for correcting slice data.

The cutting information generation unit 46 generates cutting information Dcu indicating a portion to be cut of the bead formed along the trajectory indicated by the corrected trajectory data Dt′ generated by the trajectory data correction unit 45 and the timing of cutting the portion.

Here, the portion to be cut of the bead is the extended portion from the start point in the trajectory data Dt to the new start point in the corrected trajectory data Dt′, and the extended portion from the end point in the trajectory data Dt to the new end point in the corrected trajectory data Dt′. It should be a part. However, one or both of these extended portions may not be cut. For example, if the laminate-molded article 100 has a hollow portion and it is sufficient for the fluid to flow through the hollow portion, the extending portion inside the laminate-molded article 100 may not be cut. Also, if the laminate-molded article 100 is a mold and the final product is made from molten metal that is poured into the mold, the extending portion on the outside of the laminate-molded article 100 may not be cut.

In addition, when the laminate-molded article 100 is formed, there are two timings for cutting the bead portion: cutting after all the beads are formed, and cutting each time the bead is laminated. For example, when the start point and end point set in the trajectory data Dt are extended to a new start point and a new end point outside the laminate-molded article 100 to form the corrected trajectory data Dt′, in order to reduce the number of steps , it is better to cut the extension after all the beads are formed. In addition, when extending the start point and the end point set in the trajectory data Dt to the new start point and the new end point inside the laminate-molded article 100 to obtain the corrected trajectory data Dt', cutting is performed collectively later. Therefore, it is recommended to cut the stretched portion each time the bead is laminated.

The control program generator 47 generates a control program Dp for controlling the welding robot 10 and the cutting robot 15 . Here, the control program Dp causes the welding robot 10 to perform additive manufacturing under the welding conditions Dco generated by the welding condition generation unit 44 along the trajectory indicated by the corrected trajectory data Dt′ generated by the trajectory data correction unit 45. control. Further, when the cutting information generator 46 generates the cutting information Dcu, it also controls the cutting robot 15 so that the bead portion indicated by the cutting information Dcu is cut at the timing indicated by the cutting information Dcu.

The control program output unit 48 outputs the control program Dp generated by the control program generation unit 47 to the recording medium 70 . In this embodiment, the control program Dp is used as an example of information for controlling the manufacture of the modeled object, and the control program output unit 48 is provided as an example of output means for outputting the information.

[Functional configuration of control device]
FIG. 4 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 and a control program execution section 63 .

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 control program execution unit 63 reads and executes the control program stored in the control program storage unit 62 . At that time, the control program execution unit 63 causes the welding robot 10 to perform welding under the welding conditions Dco generated by the welding condition generation unit 44 along the trajectory indicated by the corrected trajectory data Dt′ generated by the trajectory data correction unit 45. control. The control program execution unit 63 may also control the cutting robot 15 to cut the bead portion indicated by the cutting information Dcu generated by the cutting information generation unit 46 at the timing indicated by the cutting information Dcu.

[Operation of lamination planning device]
FIG. 5 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 section 41 acquires the three-dimensional CAD data D3d from the CAD device 20 (step 301).

Next, the CAD data division unit 42 divides the three-dimensional CAD data D3d acquired in step 301 into a plurality of layers to generate layer shape data Ds (step 302).

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

Also, the welding condition generation unit 44 generates welding conditions Dco, which are conditions for forming a bead, based on the layer shape data Ds generated in step 302 and the trajectory data Dt generated in step 303. (Step 304).

Next, the trajectory data correction unit 45 corrects the trajectory data Dt generated in step 303 so as to extend the start point and end point of the bead to the new start point and new end point, respectively, thereby generating corrected trajectory data Dt'. (step 305).

Also, the welding condition generator 44 changes the welding condition Dco generated in step 304 based on the corrected trajectory data Dt' generated in step 305 (step 306). Specifically, the welding speed of the extended portion from the start point and end point of the bead to the new start point and new end point is made lower than the welding speed of the portion other than the extended portion of the bead.

Further, the cutting information generation unit 46 generates cutting information Dcu indicating the portion to be cut of the bead formed along the trajectory indicated by the corrected trajectory data Dt′ generated in step 305 and the timing of cutting the portion ( step 307).

Next, the control program generator 47 generates the welding robot 10 based on the corrected trajectory data Dt' generated in step 305, the welding conditions Dco generated in step 306, and the cutting information Dcu generated in step 307. And a control program Dp for controlling the cutting robot 15 is generated (step 308). Specifically, the control of the welding robot 10 that welds along the trajectory indicated by the corrected trajectory data Dt′ under the welding conditions Dco, and the cutting robot 15 that cuts the bead portion indicated by the cutting information Dcu at the timing indicated by the cutting information Dcu. to generate a control program Dp that controls

Finally, the control program output unit 48 outputs the control program Dp generated in step 308 to the recording medium 70 (step 309).

[Operation of the 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 and the cutting robot 15, the control program execution unit 63 reads out the control program stored in the control program storage unit 62 and executes it. Execute.

Here, as an operation example of the control program execution unit 63, two different operation examples are conceivable according to the cutting timing indicated by the cutting information Dcu. One is an operation example in which all the beads for n layers are laminated and then the stretched portions for n layers are collectively cut. The other is an operation example in which n layers of beads are laminated while cutting the extended portion of the layer each time one layer of beads is laminated. Hereinafter, the former will be described as a first operation example, and the latter will be described as a second operation example.

FIG. 6 is a flow chart showing a first operation example of the control program execution unit 63. As shown in FIG.

The control program execution unit 63 first sets the index i of the layer forming the laminate-molded article 100 to 1 (step 501).

Next, the control program execution unit 63 forms the i-th layer bead while incrementing the index i from 1 to n by 1, thereby forming the beads from the first layer to the n-th layer bead. . That is, the control program execution unit 63 controls the welding robot 10 to form the i-th bead from the new start point set in the i-th corrected trajectory data Dt′(i) toward the new end point. (step 502). The control program execution unit 63 also adds 1 to the index i (step 503) and determines whether the index i exceeds n (step 504). If the control program execution unit 63 determines that the index i does not exceed n, there are still beads to be formed, so the process returns to step 502 . On the other hand, if it is determined that the index i has exceeded n, then the process proceeds to step 505 because the beads up to the n-th layer have been formed.

After that, the control program execution unit 63 controls the cutting robot 15 to collectively cut the extended portions from the start point and end point to the new start point and new end point of the bead of the 1st to n-th layers (step 505 ) and terminate the process.

FIG. 7 is a flow chart showing a second operation example of the control program execution unit 63. As shown in FIG.

The control program execution unit 63 first sets the index i of the layer constituting the laminate-molded article 100 to 1 (step 551).

Next, the control program execution unit 63 increments the index i from 1 to n by 1 and forms the bead of the i-th layer while cutting the extending portion of the bead to form the bead of the i-th layer. Perform processing to form beads. That is, the control program execution unit 63 controls the welding robot 10 to form the i-th bead from the new start point set in the i-th corrected trajectory data Dt′(i) toward the new end point. (step 552). Then, for the i-th layer bead, the cutting robot 15 is controlled so as to cut the extending portion from the start point and end point to the new start point and new end point in the i-th corrected trajectory data Dt'(i) (step 553). ). The control program execution unit 63 also adds 1 to the index i (step 554) and determines whether the index i exceeds n (step 555). If the control program execution unit 63 determines that the index i does not exceed n, there are still beads to be formed, so the process returns to step 552 . On the other hand, if it is determined that the index i has exceeded n, the bead has been formed up to the n-th layer, and the process ends.

[Concrete example]
The modeling of the laminate-molded article 100 using the metal additive manufacturing system 1 will be described with a specific example. Here, a case of forming a cylindrical laminate-molded article 100 on a rectangular base material 90 is taken as an example.

First, various data used for modeling the laminate-molded article 100 will be described.

FIG. 8 shows an example of the three-dimensional CAD data D3d. The three-dimensional CAD data D3d is actually expressed in a binary format, an ASCII format, or the like, but is schematically represented here to aid understanding.

The three-dimensional CAD data D3d shown in FIG. 8 is generated by the CAD device 20 and acquired by the CAD data acquisition section 41 of the stacking planning device 30, as described above.

FIG. 9A shows an example of layer shape data Ds. FIG. 9(b) shows an example of layer shape data Ds(1) of the first layer that constitutes the layer shape data Ds shown in FIG. 9(a). The layer shape data Ds and the layer shape data Ds(1) of the first layer are also expressed in a binary format, an ASCII format, or the like in practice, but are represented here schematically for the sake of understanding. ing.

The layer shape data Ds shown in FIG. 9A is generated by the CAD data dividing section 42 of the stacking planning device 30 as described above. In this example, the layer shape data Ds has an n-layer structure including layer shape data Ds(1) for the first layer to layer shape data Ds(n) for the n-th layer.

Also, the layer shape data Ds(1) of the first layer shown in FIG. 9(b) has an annular shape corresponding to the cylindrical shape of the original three-dimensional CAD data D3d.

Although not described in detail here, each of the layer shape data Ds(2) of the second layer to the layer shape data Ds(n) of the n-th layer also has an annular shape. In this example, the layer shape data Ds(1) of the first layer to the layer shape data Ds(n) of the n-th layer have the same shape.

FIG. 10(a) shows an example of the trajectory data Dt. Also, FIG. 10(b) shows an example of the first-layer trajectory data Dt(1) that constitutes the trajectory data Dt shown in FIG. 10(a). Note that the trajectory data Dt and the trajectory data Dt(1) of the first layer are also expressed in a binary format, an ASCII format, or the like in practice, but are represented schematically here to aid understanding. .

The trajectory data Dt shown in FIG. 10A is generated by the trajectory data generator 43 of the stacking planning device 30 as described above. In this example, the trajectory data Dt has an n-layer structure including the trajectory data Dt(1) of the first layer to the trajectory data Dt(n) of the n-th layer. However, in FIG. 10(a), for the convenience of drawing, only the track data Dt(n) of the n-th layer is indicated by a solid line, and the track data Dt(1) to (n-1) of the first layer are shown by solid lines. A portion of the trajectory data Dt(n-1) is indicated by a dashed line. FIG. 10A also shows a start point Ps(n) and an end point Pe(n) of the n-th layer, which will be described later.

Also, the trajectory data Dt(1) of the first layer shown in FIG. It's becoming

Further, in the trajectory data Dt(1) of the first layer, the start point Ps(1) and the end point Pe(1) are placed on the periphery of the original layer shape data Ds(1). is set. As a result, the trajectory data Dt(1) of the first layer can be expressed in one pass (so-called one-stroke writing) along the circumference from the starting point Ps(1) to the ending point Pe(1). there is

Although not described in detail here, the trajectory data Dt(2) of the second layer to the trajectory data Dt(n) of the n-th layer also have the start point Ps(2) and the end point Pe(2) to A start point Ps(n) and an end point Pe(n) are set. In this example, the trajectory data Dt(1) of the first layer to the trajectory data Dt(n) of the n-th layer having a common shape have the starting point Ps(1) and the ending point Pe(1) to the starting point Ps(n ) and the end point Pe(n) are arranged so as to overlap each other when viewed from above in the vertical direction.

FIG. 11(a) shows an example of corrected trajectory data Dt'. FIG. 11(b) shows an example of first-layer corrected trajectory data Dt'(1) that constitutes the corrected trajectory data Dt' shown in FIG. 11(a). The corrected trajectory data Dt' and the corrected trajectory data Dt'(1) of the first layer are also expressed in a binary format, an ASCII format, or the like in practice. expressing.

The corrected trajectory data Dt' shown in FIG. 11(a) is generated by the trajectory data correction unit 45 of the stacking planning device 30 as described above. In this example, the corrected trajectory data Dt' has an n-layer structure including the first layer corrected trajectory data Dt'(1) to the n-th layer corrected trajectory data Dt'(n). However, in FIG. 11(a), for the convenience of drawing, only the corrected trajectory data Dt'(n) of the n-th layer is indicated by a solid line, and the corrected trajectory data Dt'(1) to (n−1) of the first layer are shown by solid lines. )-th layer corrected trajectory data Dt'(n-1) is partly indicated by a broken line. FIG. 11A also shows a start point Ps(n) and an end point Pe(n) of the n-th layer, a new start point Ps'(n) and a new end point Pe'(n), which will be described later.

Further, the corrected trajectory data Dt'(1) of the first layer shown in FIG. 11B is basically Although it has a circular shape, one end of the track protrudes outside the circumference and the other end of the track protrudes inside the circumference. Specifically, the first-layer corrected trajectory data Dt'(1) shown in FIG. to a new starting point Ps'(1), and modifying the end point Pe(1) to extend to a new end point Pe'(1) inside the perimeter.

Although not described in detail here, each of the corrected trajectory data Dt'(2) of the second layer to the corrected trajectory data Dt'(n) of the n-th layer also has a new starting point Ps'(2). And a new end point Pe'(2) to a new start point Ps'(n) and a new end point Pe'(n) are set. In this example, a new start point Ps'(1) and a new end point Ps'(1) are added to the first-layer corrected trajectory data Dt'(1) to the n-th layer corrected trajectory data Dt'(n) having a common shape. Pe'(1) to the new start point Ps'(n) and the new end point Pe'(n) are also arranged so as to overlap each other when viewed vertically from above.

By the way, regarding the new start point Ps' and the new end point Pe', as described above, one is set outside the circumference and the other is set inside the circumference, and both are set outside the circumference. There are three modes: a mode in which both are set inside the circumference. FIGS. 11(a) and 11(b) show corrected trajectory data Dt′ when the first of these three modes is adopted, but the second or third The first aspect may be adopted.

Next, a manufacturing process of the laminate-molded article 100 using various data shown in FIGS. 8 to 11 will be described.

12A to 12D are diagrams showing a first example of the manufacturing process of the laminate-molded article 100. FIG. This laminate-molded article 100 employs a mode in which the new start point Ps' and the new end point Pe' are both set outside the circumference, out of the above three modes. Further, by adopting this mode, the operation of the manufacturing process is described as the first operation example of the control program execution unit 63. After laminating all the beads for n layers, the extended portions for n layers are collectively cut. This is an operation example. Here, the case where the total number of layers of the beads 101 constituting the laminate-molded article 100 is 5 (n=5) will be described as an example.

FIG. 12(a) is a perspective view showing a state after forming the first-layer bead 101(1) on the base material 90 based on the first-layer corrected trajectory data Dt'(1).

Here, the first-layer corrected trajectory data Dt′(1), which is the source of the first-layer bead 101(1), includes the first-layer start point Ps(1) and the first-layer end point Pe(1). , a new start point Ps'(1) for the first layer, and a new end point Pe'(1) for the first layer. These start point Ps(1), end point Pe(1), new start point Ps'(1), and new end point Pe'(1) are shown in the perspective view of FIG. It does not actually appear in the real world, but is shown virtually.

Then, the welding robot 10 moves the filler material 14 held by the welding torch 13 on the base material 90 along the trajectory indicated by the corrected trajectory data Dt'(1) for the first layer. from the starting point Ps'(1) to the new end point Pe'(1) of the first layer via the starting point Ps(1) of the first layer and the end point Pe(1) of the first layer. Thus, as shown in FIG. 12(a), beads 101(1) of the first layer are formed on the base material 90. Next, as shown in FIG. At that time, the bead 101(1) of the first layer includes an extending portion from the starting point Ps(1) of the first layer to a new starting point Ps'(1) of the first layer, and an end point Pe( 1) to the new end point Pe'(1) of the first layer.

FIG. 12B shows the state after the second layer bead 101(2) is formed on the first layer bead 101(1) based on the second layer corrected trajectory data Dt'(2). It is a perspective view showing.

Here, the second layer start point Ps(2) and the second layer end point Pe(2) are also included in the second layer corrected trajectory data Dt'(2), which is the basis of the second layer bead 101(2). , a new start point Ps'(2) for the second layer, and a new end point Pe'(2) for the second layer are set. These start point Ps(2), end point Pe(2), new start point Ps'(2), and new end point Pe'(2) are shown in the perspective view of FIG. It does not actually appear in the real world, but is shown virtually. In this example, since the corrected trajectory data Dt'(1) of the first layer and the corrected trajectory data Dt'(2) of the second layer have the same shape, the starting point Ps ( 2) is the start point Ps(1) of the first layer, the end point Pe(2) of the second layer is the end point Pe(1) of the first layer, and the new start point Ps'(2) of the second layer is the first layer. The new start point Ps'(1) of the second layer and the new end point Pe'(2) of the second layer overlap the new end point Pe'(1) of the first layer.

Then, the welding robot 10 moves the filler metal 14 held by the welding torch 13 along the trajectory indicated by the second-layer corrected trajectory data Dt'(2) on the first-layer bead 101(1). , from a new start point Ps'(2) on the second layer, via a start point Ps(2) on the second layer and an end point Pe(2) on the second layer, a new end point Pe'(2 ). As a result, as shown in FIG. 12B, the beads 101(2) of the second layer are formed on the beads 101(1) of the first layer. At that time, the bead 101(2) of the second layer includes an extended portion from the start point Ps(2) of the second layer to a new start point Ps'(2) of the second layer and the end point Pe( 2) to the new end point Pe'(2) of the second layer are formed.

Subsequently, the beads 101(3) of the third layer, the beads 101(4) of the fourth layer, and the beads 101(5) of the fifth layer are laminated in the same procedure.

In FIG. 12(c), the fifth-layer bead 101(5), which is the final layer, is formed on the fourth-layer bead 101(4) based on the fifth-layer corrected trajectory data Dt'(5). It is a perspective view showing a state after.

In the case of this embodiment, the shape of the object after forming the bead 101 (5) of the fifth layer is that the shape of the original cylindrical object is a protrusion 102 extending along the vertical direction on the outer peripheral surface side of the original cylindrical object. (First-layer protrusion 102(1) to fifth-layer protrusion 102(5)) are formed.

FIG. 12(d) shows a laminate-molded article 100 obtained by machining the molded article shown in FIG. 12(c).

The cutting robot 15 uses the metalworking tool 18 to cut the projections 102 of the first layer on the beads 101(1) to 101(5) of the first layer to the bead 101(5) of the first layer shown in FIG. Machining is performed to cut the protrusions 102(5) of the fifth layer from (1). As a result, the layered product 100 having a shape close to the shape of the original modeled product (three-dimensional CAD data D3d) is obtained.

13A to 13F are diagrams showing a second example of the manufacturing process of the laminate-molded article 100. FIG. This laminate-molded article 100 employs a mode in which the new start point Ps' and the new end point Pe' are both set inside the circumference of the above three modes. Further, by adopting this mode, the operation of the manufacturing process is shown as the second operation example of the control program execution unit 63. Each time one layer of beads is laminated, the extending portion of the layer is cut and n layers are formed. This is an operation example of laminating beads for 10 minutes. Here, too, the case where the total number of layers of the beads 101 constituting the laminate-molded article 100 is 5 (n=5) will be described as an example.

FIG. 13(a) is a perspective view showing a state after the first-layer bead 101(1) is formed on the base material 90 based on the first-layer corrected trajectory data Dt'(1).

Here, the first-layer corrected trajectory data Dt′(1), which is the source of the first-layer bead 101(1), includes the first-layer start point Ps(1) and the first-layer end point Pe(1). , a new start point Ps'(1) for the first layer, and a new end point Pe'(1) for the first layer. These start point Ps(1), end point Pe(1), new start point Ps'(1), and new end point Pe'(1) are shown in the perspective view of FIG. It does not actually appear in the real world, but is shown hypothetically.

Then, the welding robot 10 moves the filler material 14 held by the welding torch 13 on the base material 90 along the trajectory indicated by the corrected trajectory data Dt'(1) for the first layer. from the starting point Ps'(1) to the new end point Pe'(1) of the first layer via the starting point Ps(1) of the first layer and the end point Pe(1) of the first layer. Thus, as shown in FIG. 13(a), beads 101(1) of the first layer are formed on the base material 90. Next, as shown in FIG. At that time, the bead 101(1) of the first layer includes an extending portion from the starting point Ps(1) of the first layer to a new starting point Ps'(1) of the first layer, and an end point Pe( 1) to the new end point Pe'(1) of the first layer.

FIG. 13(b) is a perspective view showing a state after cutting the protrusion 102(1) of the bead 101(1) of the first layer shown in FIG. 13(a).

The cutting robot 15 uses the metal working tool 18 to machine the bead 101(1) of the first layer shown in FIG. . As a result, as shown in FIG. 13B, the protrusion 102(1) of the bead 101(1) of the first layer is removed.

FIG. 13(c) shows the state after the second layer bead 101(2) is formed on the first layer bead 101(1) based on the second layer corrected trajectory data Dt'(2). It is a perspective view showing.

Here, the second layer start point Ps(2) and the second layer end point Pe(2) are also included in the second layer corrected trajectory data Dt'(2), which is the basis of the second layer bead 101(2). , a new start point Ps'(2) for the second layer, and a new end point Pe'(2) for the second layer are set. These start point Ps(2), end point Pe(2), new start point Ps'(2), and new end point Pe'(2) are shown in the perspective view of FIG. It does not actually appear in the real world, but is shown virtually. In this example, since the corrected trajectory data Dt'(1) for the first layer and the corrected trajectory data Dt'(2) for the second layer have the same shape, the data for the second layer The start point Ps(2) of is the first layer start point Ps(1), the second layer end point Pe(2) is the first layer end point Pe(1), and the second layer new start point Ps'(2 ) overlaps the new start point Ps'(1) of the first layer, and the new end point Pe'(2) of the second layer overlaps with the new end point Pe'(1) of the first layer. However, in reality, since the protrusion 102(1) is removed, one layer The new start point Ps'(1) of the eye and the new end point Pe'(1) of the first layer do not exist. Also, this removal of protrusion 102(1) may cause protrusion 102(2) to droop, but this does not significantly affect subsequent cutting.

Then, the welding robot 10 moves the filler metal 14 held by the welding torch 13 along the trajectory indicated by the second-layer corrected trajectory data Dt'(2) on the first-layer bead 101(1). , from a new start point Ps'(2) on the second layer, via a start point Ps(2) on the second layer and an end point Pe(2) on the second layer, a new end point Pe'(2 ). As a result, as shown in FIG. 13C, the beads 101(2) of the second layer are formed on the beads 101(1) of the first layer. At that time, the bead 101(2) of the second layer includes an extended portion from the start point Ps(2) of the second layer to a new start point Ps'(2) of the second layer and the end point Pe( 2) to the new end point Pe'(2) of the second layer are formed.

FIG. 13(d) is a perspective view showing a state after the protrusion 102(2) of the bead 101(2) of the second layer shown in FIG. 13(c) is cut.

The cutting robot 15 uses the metal processing tool 18 to machine the bead 101(2) of the second layer shown in FIG. . As a result, as shown in FIG. 13(d), the protrusion 102(2) of the bead 101(2) of the second layer is removed.

Thereafter, in the same procedure, lamination of beads 101 (3) of the third layer, cutting of protrusions 102 (3) of the third layer, lamination of beads 101 (4) of the fourth layer, and protrusions of the fourth layer 102(4) is cut and the fifth layer of beads 101(5) is laminated.

In FIG. 13(e), the fifth-layer bead 101(5), which is the final layer, is formed on the fourth-layer bead 101(4) based on the fifth-layer corrected trajectory data Dt'(5). It is a perspective view showing a state after.

FIG. 13(f) is a perspective view showing a state after cutting the protrusion 102(5) of the bead 101(5) of the fifth layer shown in FIG. 13(e).

The cutting robot 15 uses the metal working tool 18 to machine the bead 101(5) of the fifth layer shown in FIG. . As a result, as shown in FIG. 13(f), the protrusion 102(5) of the bead 101(5) of the fifth layer is removed. Then, a laminate-molded article 100 having a shape close to the shape of the original molded article (three-dimensional CAD data D3d) is obtained.

By the way, regarding the new start point Ps' and the new end point Pe', in FIGS. A mode in which both are set inside the circumference was adopted. However, the same explanation can be given for the case where one is set on the outside of the circumference and the other is set on the inside of the circumference.

In this case, there are three possible operations of the manufacturing process. The first is an operation of laminating all the beads for n layers and then collectively cutting the outer and inner extended portions for n layers. The second is an operation of laminating n layers of beads while cutting the outer and inner stretched portions of the layer each time one layer of beads is laminated. The third method is to laminate n layers of beads while cutting the inner stretched portion of the layer each time one layer of beads is stacked, and then cut the n layers of outer stretched portions collectively. It is action. Which of these three operations should be performed should be determined in consideration of the mechanical features of the welding robot 10 and the cutting robot 15 .

[Modification]
In the present embodiment, the stacking planning device 30 generates the trajectory data Dt and corrects it to generate the corrected trajectory data Dt', but the present invention is not limited to this. The lamination planning device 30 may generate the trajectory data Dt, and the control device 50 may generate the corrected trajectory data Dt' by correcting the trajectory data Dt.

Further, in the present embodiment, when all the beads for n layers are laminated and then the extending portions for n layers are collectively cut, the cutting robot 15 provided separately from the welding robot 10 cuts the extending portions for the n layers. is cut, but it is not limited to this. The welding torch 13 of the welding robot 10 may be replaced with a metal working tool 18 and driven as a cutting robot to cut the extended portion for n layers.

Furthermore, in the present embodiment, when all the beads for n layers are laminated and then the stretched portions for n layers are cut together, the cutting robot 15 included in the metal additive manufacturing system 1 cuts the stretched portions for n layers. Although cutting is used, the present invention is not limited to this. In a process different from the process of laminating beads for n layers by the metal additive manufacturing system 1 , the extended portion for n layers may be cut by means not included in the metal additive manufacturing system 1 .

[Effects of this embodiment]
As described above, in the present embodiment, for example, when creating a trajectory plan from the three-dimensional CAD data D3d, the points at which the arc is turned on or off are adjusted. As a result, it is possible to prevent the occurrence of defects from concentrating on a specific portion of the final laminate-molded article 100 .

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... Welding condition generation part , 45... Trajectory data correction unit 46... Cutting information 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... Control program execution unit 70... Recording medium

Claims (9)

A manufacturing method for manufacturing a modeled product including a laminated body in which a plurality of beads formed by melting and solidifying a filler material using an arc is produced based on three-dimensional shape data,
Determining the start point and end point of the bead in each layer from the slice data obtained by dividing the three-dimensional shape data into a plurality of layers;
modifying the slice data to extend the start point and the end point to a new start point and a new end point, respectively, located outside the modeled object;
manufacturing the shaped object by forming a bead from the new starting point toward the new end point based on the modified slice data ;
In the correcting step, the start point and the end point are extended to the new start point and the new end point on one side of the modeled object, respectively, and a portion extending from the start point to the new start point and from the end point A method for manufacturing a modeled object , wherein the slice data is corrected so as to form a projection formed of a portion extended to the new end point . The modeled object is cylindrical,
2. The method of claim 1, wherein one side of the shaped article is an outside of the shaped article . 3. The method of manufacturing a model according to claim 2 , further comprising the step of cutting said protrusions in all beads after all beads are formed in said manufacturing step. The modeled object is cylindrical,
2. The method of manufacturing a model according to claim 1, wherein one side of the model is an inner side of the model . 5. The method of manufacturing a modeled object according to claim 4 , wherein in the manufacturing step, the projecting portion of the laminated bead is cut each time the bead is laminated. 2. The method of manufacturing a shaped article according to claim 1, wherein in the manufacturing step, the stretched portion of the bead is formed at a lower speed than the portion of the bead other than the stretched portion. A manufacturing control method for a model, comprising:
a step of obtaining the start point and end point of a bead in each layer of slice data obtained by dividing the three-dimensional shape data into a plurality of layers;
modifying the slice data to extend the start point and the end point to a new start point and a new end point, respectively, located outside the modeled object;
outputting information for manufacturing the modeled object by forming a bead from the new start point toward the new end point based on the corrected slice data ;
In the correcting step, the start point and the end point are extended to the new start point and the new end point on one side of the modeled object, respectively, and a portion extending from the start point to the new start point and from the end point A manufacturing control method for a modeled object, wherein the slice data is corrected so as to form a projecting portion including a portion extended to the new end point . Based on three-dimensional shape data, a model manufacturing control device that controls the production of a model including a laminated body in which a plurality of beads formed by melting and solidifying a filler material using an arc is stacked,
Acquisition means for acquiring a start point and an end point of a bead in each layer of slice data obtained by dividing the three-dimensional shape data into a plurality of layers;
a correction means for correcting the slice data so as to extend the start point and the end point to a new start point and a new end point located outside the modeled object, respectively;
an output means for outputting information for manufacturing the modeled object by forming a bead from the new start point toward the new end point based on the corrected slice data ;
The modifying means extends the start point and the end point to the new start point and the new end point on one side of the modeled object, respectively, and extends a portion from the start point to the new start point and from the end point to the new end point. A production control apparatus for a modeled object, wherein the slice data is corrected so as to form a projection including a portion extended to a new end point . Based on the three-dimensional shape data, the computer functions as a production control device for the model, which controls the production of the model including a laminate of multiple layers of beads made by melting and solidifying the filler material using an arc. A program for
said computer,
Acquisition means for acquiring a start point and an end point of a bead in each layer of slice data obtained by dividing the three-dimensional shape data into a plurality of layers;
a correction means for correcting the slice data so as to extend the start point and the end point to a new start point and a new end point located outside the modeled object, respectively;
By forming a bead from the new start point toward the new end point based on the corrected slice data, functioning as output means for outputting information for manufacturing the modeled object ,
The modifying means extends the start point and the end point to the new start point and the new end point on one side of the modeled object, respectively, and extends from the start point to the new start point and from the end point to the new end point. A program for modifying the slice data so that a protrusion consisting of an extension to a new end point is formed .

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