WO2014158121A1

WO2014158121A1 - Device for modelling and manufacturing three-dimensional bodies

Info

Publication number: WO2014158121A1
Application number: PCT/UA2013/000059
Authority: WO
Inventors: Олэг Анатолийовыч ПЭРЭТЯТЬКО
Original assignee: Peretiatko Oleh Anatoliiovych
Priority date: 2013-03-28
Filing date: 2013-06-10
Publication date: 2014-10-02
Also published as: UA80998U

Abstract

The invention relates to means for modelling and manufacturing three-dimensional bodies. The device comprises a computer which operates using mathematical models, and a controller, which receives information relating to the coordinates of an actuating element controlled by the controller, in which the actuating element comprises a worktable, which consists of a stand and a platform mounted thereon, said platform having a rigid structure, on which actuating devices having feedback are arranged in a specific order and fixed, wherein the status of the actuators (actuating devices) is determined by the controllers implementing the commands of the computer. The technical result consists in automatic correction of a virtual mathematical model.

Description

DEVICE FOR MODELING AND MANUFACTURE OF VOLUME BODIES

The utility model relates to mechanical devices for modeling and

physical reproduction of the template, followed by the manufacture of matrices for molding the product or parts of the bulk product.

There are various devices for this purpose. A known method of rapid prototyping is layer-by-layer (additive) creation of a physical object that exactly corresponds to a virtual 3D mathematical model. In this case, all the elements of the created object point by point are sequentially placed according to the coordinates specified by the software. Modeling with 3D printers has many advantages and is ideal for creating small objects from certain materials, but today equipment and materials are very expensive and this method does not solve the technical problem of modeling relatively large objects.

A device for the manufacture of three-dimensional objects is known, patent US N ° 5 121 329 (B22F 3/1 15; B22F 3/00; B29C 41/36; B29C 41/34; B29C 67/00; G05B 19/4097; G05B 19/4099 ; G05B 19/41; G06F 015/46), date of issue June 9, 1992).

This device for the manufacture of three-dimensional physical objects of a predetermined shape by means of successively applied multiple layers of hardening material on a base element in the desired manner, includes: A movable head having a channel device connected to a metering outlet at one end, as a result of which said metering outlet the hole contains a tip with a nozzle, the supply of material hardening at a given temperature and a device for bringing this material into liquid a state inside the aforementioned channel device, a closely spaced base element operating close to the aforementioned spray head, and mechanical devices for moving the aforementioned spray head and

the aforementioned base element relative to each other in three dimensions along axes "X,""Y," and "Ζ" in a rectangular coordinate system in a predetermined sequence and in a predetermined manner, as well as to offset the mentioned spray head by a predetermined increasing distance relative to the base element and, as a consequence, relative to each subsequent layer set aside before, for the beginning of the formation of each subsequent layer to form a plurality of layers of the specified material of a predetermined thickness, which grow one on one in succession, as they harden after leaving an aforementioned nozzle, and means for dispensing the aforementioned material ejected as a liquid current from the aforementioned nozzle with a predetermined intensity onto the aforementioned base element to form the aforementioned three-dimensional object while the above spray head and the base element move each other

relative to a friend.

However, the known device has the following disadvantages:

1. The complex device for the preparation, supply and use of hardening

material for obtaining three-dimensional physical objects.

2. A long process of sequential buildup of many layers at

receiving an object.

3. The impossibility of adjusting the shape of the obtained object after the solidification of its constituent material.

The closest set of essential features to the claimed utility model and adopted as a prototype is the device "Computer automated manufacturing process and system", patent number US N ° 4 665 492 (B29C 41/36; B29C 41/34; B29C 67/00; G05B 19/41; G06F 015/46), the release date is May 12, 1987, consisting of a computer system that consists of a computer that works with mathematical models, a machine controller that receives information about the coordinates and the executive body that the controller controls.

The computer creates a file with coordinates that display a three-dimensional computer model of the object in a three-dimensional coordinate system. A file with coordinates is transmitted and received by the controller, which controls the servo mechanism. The servo mechanism, in turn, controls the movable ejection head, which emits a stream of material particles, which, due to the push or attraction, are directed to the point of the three-dimensional object with the necessary coordinates in the three-dimensional coordinate system. The stream can consist of ejected particles or droplets containing a particular substance, or it can be a stream converted into particles of material already in the chamber, attracted to the seed grain, or to a point with other coordinates.

The movement of the working head, or heads, under the control of a computer in

in accordance with the information on the coordinates representing the model, a physical three-dimensional object or object can be automatically constructed in

according to the model, and can be built from seed grain.

Analysis of the technical characteristics of the prototype showed the presence of a number of significant drawbacks.

1. The presence in the composition of the prototype of complex mechanical drives.

2. The material forming the three-dimensional objects is a liquid.

3. It takes time to harden the material

4. small amount of space in which the simulation takes place

5. Difficult to adjust the shape of the finished product.

The utility model is based on the technical task: to develop a set of equipment for modeling and subsequent production of medium- and

bulky products having volumetric (mainly bas-relief) forms.

- equipment should provide the ability to create a mathematical model of a given volumetric object (subject);

- equipment should provide the ability to use mathematical models created on other equipment for specified volumetric objects (objects);

- scale and reduce to a single coordinate system, necessary for the further accurate operation of all components of the equipment;

- select the bending lines and planes necessary for reproduction;

- project (reproduce) on the executive apparatus, then - the stand, the elements selected for work; - Correct the geometry of individual bending lines and planes of the mathematical model, while simultaneously changing the projection geometry (physical model of the future template) on the working surface of the stand, while being able to correct the physical model on the stand in manual mode, changing, as a result, the shape of the virtual mathematical model that is, to send signals through the controllers to the elements of the actuator to change its position, after which, according to the feedback scheme, receive address signals for automatically sky correction of elements of a virtual mathematical model;

- receive as soon as possible on the stand a template, shape, (matrix, imprint, impression of both convex, negative and depressed, positive) lines or planes with relief or geometry corresponding to a virtual mathematical model, in a given scale and with physical properties that allow the use of it as a matrix for further molding;

- provide for the combined use of several stands to obtain patterns of large or complex shapes. Subsequently manufactured elements

are combined into a single product;

- both manufacturing methods and materials may be different, depending on the size, purpose and other requirements of the product.

The technical task posed can be carried out by the implementation of the claimed “Device for modeling and manufacturing volumetric bodies”, which consists of a computer equipped with software that allows you to create, modify and save a mathematical model of the surface of the object in the given scale and coordinates, a control unit consisting of a system of controllers that receive information about the coordinates, and actuators - stands

controlled by controllers. Correction at the stand of the physical model in manual mode with a change, as a result, of the shape of the virtual mathematical model, can be performed by the operator when working directly with the above-mentioned computer, or by means of a remote hand control panel.

The essence of the utility model is illustrated by the drawing, which shows a block diagram of a device for the manufacture of volumetric bodies. As shown in the block diagram, the claimed device contains a 3D scanner (1), a computer (2), a controller block (3), a simulation stand (4), a production stand (5), a manual control panel (6). 3D scanning can be used as one of the ways to create a virtual mathematical model of an object, the shape of which is subject to further production.

A mathematical model can be created either using a scanner (1), or by an operator in one of the 3D modeling programs, or by modeling a physical model on a modeling bench (4) by an operator using a manual control panel (6) with its further transformation into a mathematical one, or a model already exists, and is delivered in one way or another commonly used way.

The above methods of creating a mathematical model can be applied, depending on the tasks, either comprehensively or individually.

Computer (2) has sufficient computing power, is equipped with the selected three-dimensional modeling program with the ability to save the mathematical model in one of the formats, and created software that controls the operation of the entire system in the complex.

The control unit for actuators, hereinafter referred to as the controller unit (3) is a system interfaced with a computer (2) and each of

actuators of stands (4 and 5) of controllers that convert the address signals of software or operator’s commands sent using a computer (2) or from a hand-held remote control (6) to electrical signals to control a separate actuator for moving to a given positioning point. For manual control, the operator switches the automatic control of the controllers to manual control.

The modeling stand (4) contains a working table consisting of a bed (frame) and a platform mounted above it, having a rigid structure, on which actuators are placed in a certain order and fixed, positional linear actuators are actuators having the required stroke length, sufficient margin of safety on load and feedback in the form of Hall position sensors. Horizontally located above the actuators

(attached to each actuator) structure that forms the working surface. It can be made in the form of: a) a sheet of material with the ability to stretch and deform under the influence of actuators, at the same time

retaining sufficient strength to prevent breaks, b) actuator tips of a certain, pre-calculated length, having a cross-sectional shape equilateral triangles, squares or regular hexagons,

fixed at the end of each actuator and tightly adjacent to each other (being in the same plane, forming a surface made tightly adjacent to each other by equilateral triangles, squares or hexagons) and creating a change in the above surface when the actuators move. The projections of the attachment points of the actuators to the working surface on the side, the reverse side of the attachment, are positioning points. At these points, mini touch or pressure sensors are located.

The production stand (5) is identical to the modeling stand (4) except that its working surface does not have mini touch or pressure sensors, and it can be an integral part of production equipment, for example, used as a matrix in vacuum molding equipment.

The manual control panel (6) is a touch screen interfaced with the operation of all components of the equipment through a computer (2). The software allows the operator on the above screen to observe and highlight a specific control point (actuator) and to manually adjust its position to the desired value.

The equipment, using the appropriate software, solves the problem of determining the coordinates of the surface of a virtual mathematical model relative to a virtual base site in virtual control points and generating control signals for actuators located on a production stand (5), similar to the location of virtual control points, production stand (5) in turn, has a geometry similar to a virtual base site. Occupation by each of the many actuators points

positioning corresponding to the coordinates of the control points of the virtual mathematical model solves the problem of physical reproduction of the relief of the object plane on the working surface of the production stand (5). Another task of equipment equipped with appropriate software is to be able to obtain information about changes in coordinates at positioning points when correcting a mathematical model by an operator using a hand control panel (6) and subsequent correction of a physical model at the stands. And also receive signals from position and pressure sensors, process and visually display them on a computer monitor screen (2). The claimed utility model works as follows

Option 1 (without the use of a simulation stand (4) on one base site)

The object is selected, its mathematical model is created by one of

the above methods. The dimensions of the manufactured product are set.

The operator forms a virtual base platform lying in one plane (the future base of the product or its component part) and places a virtual mathematical model over the entire plane of the object above it, taking into account the technical capabilities of the actuators - the actuator stroke length and the specified maximum height of the future product. Then the operator places in the plane of the base platform the projection of the executive apparatus - the production stand (5) with the geometry similar to its physical prototype, the number and order of placement of positioning points, scales and, if necessary, divides the mathematical model of the surface of the object into the required number of components in accordance with the dimensional data of the stand (5) and the objectives of the subsequent production. In this case, the operator places a part of the mathematical model of the product’s surface selected for work on the virtual projection of the stand. After reducing the virtual projection of the stand and the selected part of the mathematical model into a single coordinate system (along two horizontal axes), the software measures the height from the control points on the base surface to the corresponding points on the surface of the mathematical model (third axis). In the initial position, all actuators occupy the "zero" position and the working surface is even. By measuring the distances and thereby obtaining the coordinates of the control points required for positioning, the software generates address signals proportional to the measured distances to the controller unit as mismatch signals. The controllers, in turn, addressly provide electrical signals to control the actuators, which, having worked them out, push their operating rods to the positioning points and

stop in this position. The actuator position sensors signal on the computer monitor (2) about their serviceability and their occupation of the required position.

The operator is able to visually assess the quality of the formed physical model at the selected scale and, if necessary, adjust the details or return to its original position and select a different scale.

Example 1 A variant of the example operation of the claimed device:

1. We have a stand (5) with dimensions of the working surface 600x600mm. Prototype

actuator we select Haydon's hybrid linear actuator

External version (screw through the housing) with housing dimensions 28x28 mm., stroke 250 mm. and a force of 60 N. Actuators are arranged in 20 rows of 20 pieces in one row, the distance between the centers of the working rods is 30 mm.

2. We have a three-dimensional mathematical model of one side of a certain coin, the original diameter is 60 mm. and a maximum height of a clearly defined relief structure of 1.0 mm.

3. We have the set of equipment indicated on the block diagram, with the exception of the simulation stand (4).

4. We set the task: to make a bas-relief that accurately reproduces an object (coin), the mathematical model of which we have, in a given size of 6000x6000 mm. and a relief height of 100 mm, i.e. get an image of a 100 times magnified subject.

Placing actuators in a certain order on the stand is a basic coordinate system that is taken into account by the software, and under the virtual projection of which the operator brings a larger or smaller area of the mathematical model, thereby changing the scale of the future shape (cast).

In the above example, the operator virtually puts the image of the object (coin) created using the mathematical model into a square, which divides the grid into equal 10x10 = 100 shares also in the form of a square, that is, in the form of a stand, enlarging the image on the monitor to sizes convenient for work. Each of the 100 parts of the mathematical model is alternately brought into a single coordinate system with the base control points of the actuators, of which in the given example we have 400 pieces.

Having imposed a mathematical model with a relief image on the basic “grid”, we get that each of the control points (actuators) will have its own positioning point. The software and controller system solves the final problem by occupying each of the 400 actuators in a physical position in accordance with the given coordinates of points in a virtual mathematical model. Each of the 100 obtained forms, sequentially modeled and reproduced at the stand, can be realized (made) from various materials having the properties of taking a given shape with subsequent hardening and in various ways, after which they can be combined into a single product.

To obtain a product whose height of elements exceeds the technical capabilities of the production stand (5) along the actuator stroke length, modeling is performed on base planes located in the form of a pyramid, a group of pyramids or a polyhedron, the elements of which are modeled additionally and mounted as a frame.

It is also possible to divide the mathematical model not only into squares, but also into other geometric shapes that are convenient for further transportation and installation, which occupy dimensions that do not exceed the dimensions of the production stand (5) - rectangles, rhombuses, regular hexagons, shapes that go during installation " “,” one example of such a connection is the combination of puzzle elements of the puzzle type.

As a result, we obtain a device for the manufacture of a template, or the form by which the production of individual elements of the product is performed - a three-dimensional object on the necessary scale.

Option 2 using a simulation bench (4) at two base sites.

1. We have simulation stands (4) in the amount of two units, each of which is identical in size and configuration to the production stand (5) above in “option 1”, additionally equipped with mini-pressure sensors, as indicated in the description of the simulation stand (4) .

2. We have an identical production stand (5), which is part of the equipment for molding, and a set of equipment shown in the block diagram.

3. We set the tasks: 1) Create a three-dimensional mathematical model of the object for sitting, taking into account the requirements for ergonomics of the seat, individual physical parameters and anatomical features of a particular person, hereinafter - the customer.

2) Make the base of the item for sitting (seat and back), corresponding in the form of a mathematical model and in accordance with a given scale. The solution of the first problem (model creation) is carried out in two stages: preliminary and final. At the preliminary stage, one modeling bench (4) is located in a horizontal position so that the working surface is at a height corresponding to the physical parameters of the customer and the requirements for seat ergonomics (legs are bent at right angles and are firmly on the floor, etc.). Preliminary

a (draft) mathematical model of the seat can be obtained either using a 3D scanner or by properly (in accordance with ergonomics) landing of the customer on the working surface of the stand. At the same time, pressure sensors record the involved

control points, and the operator using the software determines the total load, distributes the pressure to the above points, maintaining a balance (75% of the load falls on 20-25 cm square of the area of the ischial tubercles, etc.). Since the pressure sensors work in a constant mode and give out address signals, and the control points involved (and their corresponding actuators) occupy the position determined by the software at which the sensor readings will take the given values and the whole system of actuators takes

corresponding position and is fixed. If necessary, a visual inspection is carried out, and individual sections are adjusted using the manual control panel (6). When the seat shape is satisfactory for the client, the back area is scanned with the creation of a “draft” version of the mathematical model of the back. On the back side, a second modeling stand is installed at a certain angle to the seat plane and at a short distance (4). While creating

mathematical model of the back (as an example), it can be equipped, unlike the first, not with pressure sensors, but with touch sensors. After the client has taken an equal position, all actuators, at the operator’s command, begin to move, and continue it until they touch the client in the back area, taking into account his anatomical features. The operator determines the working area, and the actuators, the corresponding points of which are outside the working area, are turned off, and all actuators in the working area continue to move until they touch, after which the position obtained

fixed. At the final (finishing) stage, the operator, according to the client’s instructions, or the client himself (previously acquainted with the terms of use) using the touch screen of the hand control panel (6) controls the position of specific actuators, that is, simulates at the same time trying on the future basis of the item for sitting to a satisfactory result. The mathematical model in the final form can be obtained both with the help of a 3D scanner, and by receiving address signals from actuator position sensors and created in a computer program according to control positioning points in a given coordinate system. A file is created in which this mathematical model is stored in one of the formats, this file is delivered to the place of further use in one way or another in a commonly used way.

The second task (manufacturing an object) is solved similarly to the first example, except that the specified scale does not change, that is, the mathematical model is not divided by the operator into sections. Let us assume that the production stand (5) is an integral part of the equipment for vacuum molding and occupies the position of a matrix (the initial form having protection against overheating). The operator on the computer monitor (2) places the selected mathematical model of the seat in the plane and coordinates corresponding to the plane and control points of the actuators of the production stand (5). The equipment complex reproduces the physical form corresponding to the mathematical model at the indicated stand, and the vacuum molding equipment according to the specified form produces the desired product from the selected sheet material. After that, all the above actions are performed with a mathematical model of the back of the subject for sitting.

As a result of the implementation of the claimed technical solution, we obtain a complex of equipment for modeling and subsequent production of medium- and large-sized products having bulk (mainly bas-relief) forms, which:

- provides the ability to create a mathematical model of a given volumetric object (subject)

- provides the ability to use created on other equipment

mathematical models of given volumetric objects (objects)

-allows you to scale and reduce into a single coordinate system, necessary for the further accurate operation of all components of the equipment;

-allows you to select the bending lines and planes necessary for reproduction;

-allows you to project (play) on the executive apparatus, then - the stand, the elements selected for work; -allows you to adjust the geometry of individual lines of bends and planes

mathematical model, at the same time changing the geometry of the projection (physical model of the future template) on the working surface of the stand.

- allows you to adjust the physical model at the stand in manual mode, changing, as a result, the shape of the virtual mathematical model.

- allows you to receive as soon as possible on the stand a template, shape, (matrix, imprint, impression of both convex, negative and depressed, positive) lines or planes with relief or geometry corresponding to a virtual mathematical model, in a given scale and with physical properties that allow using it as a matrix for further molding.

- allows the combined use of several stands to obtain patterns of large or complex shapes.

Claims

FORMULA

1. Device for modeling and manufacturing volumetric bodies, consisting of

a computer that works with mathematical models, a controller that receives information about the coordinates, and an executive body that the controller controls. characterized in that

the executive body (production stand) contains a working table consisting of a bed (frame) and a platform mounted above it, which has a rigid structure, on which actuators (positional linear actuators - actuators) are placed in a certain order and are fixed, having feedback in the form of sensors Hall position, and the state of the actuators is determined by controllers that execute computer commands,

2. A device for modeling and manufacturing volumetric bodies according to claim 1, characterized in that a sheet of material with the ability to stretch and is horizontally located (attached to each actuator) above the actuators

deform under the influence of actuators.

3. A device for modeling and manufacturing volumetric bodies according to claim 1, characterized in that at the end of each actuator there are fixed tips of a certain, pre-calculated length.

4. A device for modeling and manufacturing volumetric bodies according to claim 1, characterized in that it further comprises a modeling stand, consisting of a bed (frame) and a platform mounted above it, having a rigid structure, on which actuators are placed in a certain order and fixed

(positional linear actuators - actuators) having feedback in the form of Hall position sensors, and the state of the actuators is determined by controllers that execute computer commands, equipped with touch or pressure sensors

5. A device for modeling and manufacturing volumetric bodies according to claim 1, characterized in that it further comprises a manual control panel that receives information from a computer working with mathematical models and senses and mathematical models, operator commands

6. A device for modeling and manufacturing volumetric bodies according to claim 1, characterized in that it further comprises a scanning device.