JP2017047679A - Shaping apparatus and shaping method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To improve qualities and accuracy of a shaped object.SOLUTION: A shaping apparatus includes: a material layer forming part for forming a material layer made of a shaping material based on a given data; a transfer body for conveying the material layer transferred from the material layer forming part; and a stage for stacking the material layer conveyed by the transfer body, and the shaping apparatus manufactures a three-dimensional object made of the shaping material on the stage. The apparatus includes: a detection part for detecting a position of the material layer on the transfer body; a measuring part for measuring a positional shift of the material layer on the transfer body from the detection results of the detection part; and an adjusting part capable of adjusting a relative position between the transfer body and the stage by moving the stage in a direction orthogonal to the stacking direction of the material layer and in a rotation direction around an axis with the axial direction along the stacking direction of the material layer.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a modeling apparatus and a modeling method.

  A modeling apparatus that forms a three-dimensional model by stacking a large number of layers has been attracting attention. This type of modeling technique is called additive manufacturing (AM), three-dimensional printer, rapid prototyping (RP), or the like. Various modeling methods have been proposed for modeling technology. For example, Patent Documents 1 and 3 disclose a modeling method using an electrophotographic process, and Patent Document 2 discloses a laser sintering method.

Japanese Patent Laid-Open No. 10-224581 US Patent Application Publication No. 2009/0060386 JP 2003-053846 A

In a modeling apparatus using these methods, the shape accuracy (image formation accuracy) of the cross-sectional images of each layer and the position accuracy (stacking accuracy) when stacking the layers can greatly affect the quality of the final modeled object. In particular, as in the devices disclosed in Patent Documents 1 and 3, the problem increases in the type of stacking method in which images of each layer are formed independently and stacked in order. However, the apparatuses disclosed in Patent Documents 1 and 3 do not deal with image distortion and image position variation, and cannot guarantee image formation accuracy and stacking accuracy.
Patent Document 2 discloses a position calibration method in which a calibration plate is scanned to determine the center reference of an image before the start of modeling in a laser sintering type apparatus. However, this method cannot be applied to the type of lamination method in which images of each layer are independently formed and laminated in order as in Patent Documents 1 and 3.

  This invention is made in view of the said situation, Comprising: In the modeling apparatus of the system which forms each layer independently and laminates them in order, and obtains a three-dimensional object, For improving the quality and precision of a three-dimensional object The purpose is to provide technology.

The first aspect of the present invention is:
Based on the given data, a material layer forming unit that forms a material layer made of modeling material,
A transfer body that conveys the material layer transferred from the material layer forming section;
A stage on which the material layer conveyed by the transfer body is laminated;
A modeling apparatus for producing a three-dimensional object made of the modeling material on the stage,
A detection unit for detecting the position of the material layer on the transfer body;
A measurement unit that measures the amount of positional deviation of the material layer on the transfer body from the detection result of the detection unit;
Based on the amount of misalignment measured by the measuring unit, the stage is moved in a direction perpendicular to the stacking direction of the material layers and in a rotation direction centered on an axis whose axial direction is the stacking direction of the material layers. An adjustment unit capable of moving and adjusting a relative position between the transfer body and the stage;
A modeling apparatus is provided.

The second aspect of the present invention is:
Based on the given data, a material layer forming unit that forms a material layer made of modeling material,
A transfer body that conveys the material layer transferred from the material layer forming section;
A stage on which the material layer conveyed by the transfer body is laminated;
A modeling method using a modeling apparatus for producing a three-dimensional object made of the modeling material on the stage,
A step of adding registration marker data to data given to the material layer forming portion;
Detecting the registration marker included in the material layer on the transfer body with a detection unit;
A step of measuring a displacement amount of the material layer on the transfer body from a detection result of the detection unit by a measurement unit;
Based on the amount of misalignment measured by the measuring unit, the stage is moved in a direction perpendicular to the stacking direction of the material layers and in a rotation direction centered on an axis whose axial direction is the stacking direction of the material layers. Moving and adjusting the relative position between the transfer body and the stage;
The modeling method characterized by including this is provided.

  ADVANTAGE OF THE INVENTION According to this invention, it becomes possible to improve the quality and precision of a three-dimensional object in the modeling apparatus of the system which forms each layer independently, laminates them in order, and obtains a three-dimensional object.

Sectional drawing which shows schematic structure of the modeling apparatus of Example 1. The figure which shows an example of a structure of the control part of Example 1. The flowchart which shows the flow of the registration process in Example 1. The figure which shows the registration marker on the transcription | transfer body in Example 1. FIG. Conceptual diagram for explaining registration marker detection and correction amount calculation Conceptual diagram for explaining registration marker detection and correction amount calculation The conceptual diagram which looked at the stage correction mechanism in the lamination | stacking stage of Example 1 from the upper part. The figure for demonstrating the meandering adjustment means of Example 1. The figure which shows the other structural example of a stage correction mechanism The figure which shows the registration marker on the transcription | transfer body in Example 2. FIG. The figure which shows the registration marker on the transcription | transfer body in Example 3. Sectional drawing which shows schematic structure of the modeling apparatus of Example 4. Sectional drawing which shows schematic structure of the additive manufacturing apparatus of Example 5. Flowchart showing the flow of correction processing in the fifth embodiment. Conceptual diagram for explaining the calculation of the transfer amount of the transfer body in Example 5

The present invention relates to a modeling apparatus and a modeling method for performing a manufacturing operation (modeling operation) for manufacturing a three-dimensional object (three-dimensional object) by sequentially stacking material layers made of modeling materials.
The modeling apparatus according to the present invention converts the three-dimensional shape data of a three-dimensional object obtained by adding a support body necessary for modeling to a modeling object into slice data for modeling, and for each layer according to the slice data of each layer An image made of a modeling material is formed. And it is an apparatus which models a modeling thing by laminating | stacking the image which consists of these modeling materials in order.

As the modeling material, various materials can be selected according to the application, function, purpose, etc. of the three-dimensional object to be produced. In this specification, a material constituting a three-dimensional object that is a modeling object is referred to as a “structural material”, and a portion formed of the structural material is referred to as a structure. A material that constitutes a support body (for example, a column that supports the overhang portion from below) for supporting the structure being manufactured is referred to as a “support material”. When it is not necessary to distinguish between the two, the term “modeling material” is simply used. As the structural material, for example, a thermoplastic resin such as PE (polyethylene), PP (polypropylene), ABS, PS (polystyrene) can be used. As the support material, a material having thermoplasticity and water solubility can be preferably used in order to simplify the removal from the structure. Examples of the support material include carbohydrates, polylactic acid (PLA), PVA (polyvinyl alcohol), and PEG (polyethylene glycol).

  Further, in this specification, digital data obtained by slicing three-dimensional shape data of a three-dimensional model intended for modeling into several layers along the stacking direction is referred to as “slice data”. A layer formed of a modeling material based on slice data is referred to as a “material layer”. In addition, a target three-dimensional model (that is, a three-dimensional object represented by three-dimensional shape data given to the modeling apparatus) to be manufactured using the modeling apparatus is referred to as a “modeling object” and is manufactured (outputted) by the modeling apparatus. 3) A three-dimensional object (three-dimensional object) is called a “modeled object”. In the case where the modeled object includes the support body, a portion excluding the support body becomes a “structure” constituting the modeled object.

[Example 1]
Example 1 will be described below.
(Configuration of modeling equipment)
With reference to FIG. 1, the structure of the modeling apparatus of a present Example is demonstrated. FIG. 1 is a cross-sectional view schematically showing a schematic configuration of the modeling apparatus of the present embodiment. In FIG. 1, 1 shows a modeling apparatus main body, and the line surrounding the internal structural member shown in the figure indicates the boundary with the external space, that is, the outline.

The modeling apparatus body 1 receives slice data from an external data processing apparatus (not shown), and the material layer forming unit 2 forms a material layer 3 corresponding to the slice data using the modeling material. As this material layer forming portion, an electrophotographic system, an inkjet system, or the like can be applied.
The material layer 3 formed by the material layer forming unit 2 is transferred to the transfer surface (front surface) of the transfer body 5 which is a belt-like transport body, and is transported by the drive roller 4 to the stacking section in the direction of the arrow in the figure. The In the process of moving to the lamination part, the material layer 3 is heated and melted by the heating part 6, and the modeling material changes from a powder form to a material layer integrated into a sheet form. Here, the stacking unit includes a stacking stage 14, a transfer body 5, and a facing member 17 disposed on the inner peripheral side of the transfer body 5 so as to face the stacking stage 14. In addition, the position of the material layer 3 is detected by the non-contact position sensor (detection unit) 8 while the material layer 3 is being transported to the stack by the transfer body 5.

When the transfer body 5 is moved, it is preferable to have meandering adjusting means 7. 8A and 8B are diagrams for explaining an example of the meandering adjusting means 7, and are views when the transfer body 5 is viewed from above.
8A and 8B, the meandering adjusting means 7 is provided with a mechanism capable of independently applying a force to both ends of the rotation shaft of the driving roller 4 that stretches the transfer body 5. Thereby, it is possible to make a difference in the stretching force for stretching the transfer body 5 at both ends of the drive roller 4 in the rotation axis direction, and to adjust the meandering of the transfer body 5.

The stacking stage 14 includes a stage correction mechanism 12 and can be moved up and down by a stage up-and-down mechanism 13, and the position of the material layer 3 and the modeled object 15 can be corrected by a correction control unit described later.
In this embodiment, the modeled object 15 is formed on a base plate (base material) 9 detachably disposed on the upper surface of the stage correction mechanism 12. Therefore, the following means are provided so that the base plate 9 can be detachably positioned with respect to the stage correction mechanism 12 so that the base plate 9 does not move on the stage correction mechanism 12 during lamination. They are a positioning unit 11 for positioning the base plate 9 on the stage correction mechanism 12 and a fixed release unit 10 for attaching and detaching the base plate 9 to and from the stage correction mechanism 12.
In the modeling apparatus of the present embodiment, the transportable base plate 9 is arranged on the lamination stage 14 and the modeled object is modeled on the base plate 9, but the present invention is not limited to this. That is, the present invention can be suitably applied even to a modeling apparatus configured to model a model directly on the stacking stage (the stage correction mechanism 12 in the present embodiment).

When the material layer 3 transferred to the transfer body 5 moves to the stacking section, the stacking stage 14 is raised by the stage lifting mechanism 13 that can move the stacking stage 14 in the vertical direction (stacking direction).
Thus, the material layer 3 transferred to the transfer body 5 and heated and melted into a sheet shape is transferred between the upper surface of the model 15 on the base plate 9 positioned and fixed to the lamination stage 14 and the opposing member 17. It is sandwiched with the body 5. At this time, the material layer 3 is transferred from the transfer body 5 to the upper surface of the shaped article 15 on the base plate 9 and laminated. Thereafter, the stacking stage 14 is lowered by the stage up-and-down mechanism 13 in order to stack the material layer 3 conveyed next. By repeating this operation, a model is modeled on the base plate 9.

In this embodiment, after the modeling operation is completed, the base plate 9 and the modeled object 15 are taken out from the modeling apparatus in an integrated state.
By the time the modeling operation is finished and the next modeling operation is started, the stage correction mechanism 12 in the modeling apparatus main body 1 obtained by the origin detection unit 21 shown in FIG. Move to the origin coordinate. At that time, the transfer body 5 is rotated and returned to a predetermined center position by the meandering adjusting means 7.
By performing the adjustment sequence as described above, the correction mechanism is returned to the initial position (reference position) with respect to the modeling apparatus main body 1 before the modeling operation is completed and the next modeling operation is started.

Such a modeling process is controlled by the control unit 16. Below, the control part 16 of a present Example is demonstrated.
(Configuration of control unit)
FIG. 2 is a diagram illustrating an example of the configuration of the control unit 16 of the present embodiment. The control unit 16 includes an image generation control unit 201, a stack control unit 202, a temperature control unit 203, and a correction control unit (adjustment unit) 204.

The image generation control unit 201 has the following functions. That is, a function of generating support body data to be added according to the shape of the modeling object, and a function of generating slice data from the support body data and the three-dimensional shape data of the modeling object. Furthermore, a function for controlling the modeling apparatus main body 1 to generate the material layer 3 on the transfer body 5 by the material layer forming unit 2 from the slice data of each layer, and an addition unit for adding registration marker data to the slice data It has the function etc.
The image generation control unit 201 can generate three-dimensional shape data using data generated by a three-dimensional CAD, a three-dimensional modeler, a three-dimensional scanner, or the like. The format of the three-dimensional shape data is not limited. For example, polygon data such as STL (Stereolithography) can be preferably used. As the format of the slice data, for example, multi-value image data (each value represents a material type) or multi-plane image data (each plane corresponds to a material type) can be used. Further, the image generation control unit 201 performs resolution conversion and decoding processing of slice data, control of the formation position of the material layer 3 by the material layer forming unit 2 and the transfer timing to the transfer body. In addition, the image generation control unit 201 may have the same function as a printer controller built in a general laser printer (2D printer). In this embodiment, the image generation control unit 201 has a function of generating slice data and a function of generating three-dimensional shape data such as STL, but these functions are not necessarily included in the image generation control unit 201. It does not have to be. For example, the slice data and the three-dimensional shape data may be generated outside the modeling apparatus 1 and the result may be transmitted to the image generation control unit 201 of the modeling apparatus 1 via the network.

The stacking control unit 202 has a function of controlling the modeling apparatus main body 1 so that the material layer 3 generated on the transfer body 5 by the image generation control unit 201 is stacked on the modeling object 15 on the stacking stage 14.
Specifically, the stacking control unit 202 controls the driving roller 4 to carry the material layer 3 transferred onto the transfer body 5 to the stacking unit and temporarily stop it. Further, the stacking control unit 202 controls the movement of the stacking stage 14 and controls the material layer 3 to be stacked on the modeled object 15 formed on the base plate 9 by moving the stacking stage 14 up and down. When the control for laminating the material layer 3 on the shaped article 15 is completed, the lamination control unit 202 starts conveying the transfer body 5 again. It is efficient if the control for forming the material layer 3 is performed in parallel in the material layer forming unit 2 while the transfer body 5 is stopped.
The temperature control unit 203 controls the heating unit 6 so as to melt the material layer 3.

The correction control unit 204 has a function of adjusting a relative position between the measuring unit that measures the positional deviation amount of the material layer 3 on the transfer body 5 and the transfer body 5 and the stacking stage 14. 5 has a function of correcting the positional deviation between the material layer 3 generated on the top 5 and the shaped article 15 in the stacked portion.
As in the present embodiment, in a type of modeling apparatus in which a large number of material layers 3 are stacked to form a modeled object, the positional accuracy at the time of stacking affects the quality of the final modeled object. When the material layer of each layer is laminated on the modeling object 15 formed on the lamination stage 14, if the position variation is large, a large unevenness is formed on the side surface of the final modeling object, and a smooth surface can be obtained. Can not. Even when processing later, it takes time for the unevenness to be large. These can be said to be a problem peculiar to a modeling apparatus that forms one final model by stacking hundreds to tens of thousands of material layers.
Therefore, the correction control unit 204 of this embodiment measures the position of each material layer 3 on the transfer body 5 in order to ensure the positional accuracy at the time of stacking, and at the time of stacking, the material layer on the transfer body 5 3 and the modeled object 15 on the lamination stage 14 are aligned. In the following description, this alignment is referred to as “registration”, and the position correction function is referred to as “registration function”.

(Registration function)
Here, the registration function will be described. The registration function embeds a registration marker in the material layer, and performs alignment at the time of stacking based on the detection position of the marker.
FIG. 3 is an example of a flowchart showing the flow of registration processing in the present embodiment. Hereinafter, the flow of the registration process will be described with reference to FIG.

In step S <b> 301, in the process of forming the material layer 3, the image generation control unit 201 simultaneously forms a registration marker by the material layer forming unit 2 and transfers it to the transfer body 5 based on the registration marker data. Details of the registration marker transferred to the transfer body 5 will be described later with reference to FIG.
Next, in step S302, the stacking control unit 202 monitors the output of the non-contact position sensor 8 while moving the registration marker on the transfer body 5 toward the stacking unit. The correction control unit 204 stores the tip position and the passing distance of the registration marker detected by the non-contact position sensor 8.

Next, in step S303, the amount of displacement (correction amount) in the X direction, Y direction, and θ direction of the material layer is calculated from the detection result of the registration marker detected in step S302. Here, the X direction is the traveling (moving) direction of the transfer body 5, the Y direction is a direction orthogonal to the traveling direction of the transfer body 5, and the θ direction is the transfer body 5 to which the material layer 3 is transferred. The rotation direction is about an axis perpendicular to the transfer surface.
Next, in step S304, the correction control unit 204 controls the stacking stage 14 so as to correct the positional deviation corresponding to the positional deviation amount in the three directions calculated in step S303. Then, the stacking control unit 202 moves the stacking stage 14 up and down to stack the material layer 3 on the model 15.

FIG. 4 is a diagram illustrating an example of a registration marker on the transfer body 5 in the present embodiment. In FIG. 4, for convenience of explanation, reference numerals different from those of the configuration shown in FIG. 1 are used.
In FIG. 4, 40 corresponds to the transfer body 5, and FIG. 4 is a view when the transfer body 40 is viewed from above. 41 and 42 correspond to the non-contact position sensor 8 of FIG. In this embodiment, the non-contact position sensor 8 is an optical area sensor or a line sensor, and two sensors are arranged in a direction orthogonal to the moving direction of the transfer body 5 in association with the position where the registration marker is formed. To do. In FIG. 4, 401 has shown the area | region (henceforth modeling area | region) in which the material layer 3 can be formed on a transfer body, and a boundary may be invisible.

  In FIG. 4, reference numerals 402 and 403 denote registration markers. The registration markers 402 and 403 are formed at predetermined positions (positions that do not overlap the material layer 3) at the tip of the modeling region 401. The registration marker of the present embodiment is a right triangle shape having a first edge perpendicular to the traveling direction (X direction) of the transfer body and a second edge oblique to the X direction. Then, two registration markers are arranged in a direction orthogonal to the traveling direction of the transfer body 5 so as to be detected by each non-contact position sensor 8.

In FIG. 4, 404 corresponds to the material layer 3 formed on the transfer body by the material layer forming unit 2.
The registration markers 402 and 403 are transferred simultaneously with the material layer 404 to a predetermined position in the modeling area 401 by the material layer forming unit 2. Therefore, it is possible to acquire the amount of displacement of the material layer from the detection result of the registration marker.

(Calculation of correction amount)
5A, 5B, 5C, and 6 are conceptual diagrams for explaining registration marker detection on the transfer body 5 in step S302 of FIG. 3 and correction amount calculation in step S303.
5A, FIG. 5B, and FIG. 5C, the same code | symbol is attached | subjected about the same component as the structure shown in FIG.

  While moving the transfer body 40 upward in the figure, the registration markers 402 and 403 are detected using the fixed non-contact position sensors 41 and 42. In the figure, S1 shows an example of a signal when the non-contact position sensor 41 detects the registration marker 402. When the first edge of the registration marker 402 is detected, the signal changes from low level to high level, and when the second edge is detected, the signal changes from high level to low level. S2 similarly shows an example of a signal when the non-contact position sensor 42 detects the registration marker 403.

Here, it is assumed that the registration markers 402 and 403 are transferred with a shift of Δθ in the rotational direction from the traveling direction of the transfer body 40. In such a case, the positional deviation amount Δθ in the rotation direction can be calculated from the difference between the detection positions (detection timings) of the upper edge of the registration marker 402 and the registration marker 403. Specifically, using the known distance L1 connecting the detection centers of the non-contact position sensors 41 and 42 and the difference L2 between the detection positions of the registration marker 402 and the registration marker 403, the positional deviation amount Δθ is It can be expressed as: That is, the positional deviation amount Δθ can be expressed as Δθ = Arctan (L2 / L1) using an inverse function Arctan of the tangent Tan of the trigonometric function.

Also, ΔY is the amount of deviation of the center position of the modelable region 401 from the center position of the transfer body 40 in the Y direction, as shown in FIG. 5A, in which the registration markers 402 and 403 are perpendicular to the direction of travel of the transfer body. Is transferred with a shift of ΔY. In such a case, the positional deviation amount ΔY can be calculated using the ratio of the detection distances of the registration marker 402 and the registration marker 403. Specifically, assuming that the length of the upper edge of the triangle is 1, the following expression is established using the similarity ratio of the triangle with respect to the detection distance L3 of the registration marker 402 and the detection distance L4 of the 403. (0.5−ΔY): L3 = (0.5 + ΔY): L4ΔY = 0.5 × (L4−L3) / (L3 + L4)
Further, referring to FIG. 5C, the positional deviation amount ΔX of the registration markers 402 and 403 in the moving direction of the transfer body is obtained. The positional deviation amount ΔX is a detection distance L5 from a certain reference point on the transfer body to the upper edge of the registration markers 402 and 403. For example, the reference point may be the movement start time of the transfer body, or when the transfer body 5 is continuously operated, a marker serving as a reference position may be placed on the transfer body in advance.

In FIGS. 5A, 5B, and 5C, the amount of misregistration in the X direction, the Y direction, and the θ direction is independently calculated as having no other misregistration amount. On the other hand, even when positional deviations in the X direction, Y direction, and θ direction occur simultaneously, the positional deviation amounts in the respective directions can be obtained by geometrically combining the above calculations.
In the present embodiment, the shape of the registration marker is a right triangle, but the present invention is not limited to this shape. A figure having at least an edge perpendicular to the traveling direction of the transfer body and an edge oblique to the traveling direction can be used as the registration marker.
In this embodiment, two opposing right-angled triangular figures are used as registration markers. However, if it is known in advance that there is no deviation in the θ direction, one registration marker can be used. By using one registration marker, the amount of positional deviation in the X direction and the Y direction can be calculated.

(Noise removal processing)
The non-contact position sensors 41 and 42 of the present embodiment are assumed to be optical laser sensors.
In FIG. 5, the waveforms of the signals S1 and S2 indicating that the non-contact position sensors 41 and 42 have detected the registration markers 402 and 403 are shown as ideal waveforms.
However, as indicated by S2 ′ in FIG. 6, the actual waveform is outside the marker region due to noise 601 in the marker region due to the density of the material layer due to a decrease in transfer efficiency, or due to scratches or dents in the transfer body. Noise 602 may occur.

  The correction control unit 204 performs noise removal processing for removing these noise components in step S303 (calculation of correction amount) in FIG. Specifically, a large number of waveforms in which noise is generated is acquired in advance to create a profile, and a filtering process for removing only noise is performed. For example, by setting threshold values for the frequency of noise generated in the marker area and outside the marker area from the profile, and removing waveforms having a frequency higher than the threshold value set for each section as noise, the signal S2 in FIG. 'Can be converted into a signal S2.

By performing such processing, it is possible to calculate a correction amount that is robust to modeling accuracy of the registration marker and deterioration of the transfer body.
Further, even if the waveform obtained by the non-contact position sensors 41 and 42 has an ideal shape as shown in S2 in FIG. There is a concern that larger correction values ΔX, ΔY, and Δθ may be obtained. In order to prevent such a problem, a large amount of data is collected in advance with the configuration of this embodiment, and the maximum value and the minimum value that fall within a certain setting range are obtained. If the measured value is larger than these maximum values or smaller than the minimum value, the measured value is determined as noise and the movement amounts of ΔX, ΔY and Δθ are set to 0, and the correction mechanism 12 is not moved, i.e., 1 The correction position with respect to the material layer 3 before the layer is maintained. By performing such processing, it is possible to prevent excessive correction from being performed due to an outlier obtained by the non-contact position sensor.

(Correction process)
FIG. 7 is a conceptual view of the stage correction mechanism 12 in the stacking stage 14 of FIG. 1 as viewed from above.
The stage correction mechanism 12 executes a correction process in step S304 based on the correction amount calculated in step S303 in FIG.

  The stage correction mechanism 12 includes motors 701, 702, and 703, and the feed amounts of the respective motors for moving the base plate 704 in the X direction, the Y direction, and the θ direction are defined. The correction control unit 204 controls the motors 701, 702, and 703 so that the base plate 704 moves by the correction amounts ΔX, ΔY, and Δθ calculated in step S303. Thereby, the shift | offset | difference of the molded article 705 laminated | stacked on the baseplate 704 and the material layer 3 is eliminated.

  The correction amount of the stage correction mechanism 12 does not use the correction amount calculated in step S303 as it is when the second and subsequent material layers are stacked, but stores the previous correction position and the difference between them. It may be configured to correct only.

When it is determined that the predicted value of the correction amount is likely to exceed the correction allowance of the stage correction mechanism 12 during modeling, the control unit 16 may perform the following control. That is, the control unit 16 forms the material layer after shifting the position of the image in the material layer forming unit so that the correction amount is within the range of the correction allowance, transfer to the transfer body, and detection of the correction amount. The base plate may be moved. Examples of the method for shifting the image at the material layer forming portion include a method for processing image data, a method for shifting the position of the material layer forming portion with respect to the transfer body, and the like.
With such control, the correction cost of the stage correction mechanism 12 can be reduced, and the size and cost can be reduced.

  Further, in the configuration of the present embodiment, correction is performed by moving the shaped article 15 on the lamination stage 14 with respect to the material layer 3 on the transfer body 5, but is not limited thereto. If the transfer body 5 is configured to be movable in the X direction, the Y direction, and the θ direction, the relative displacement between the material layer 3 and the modeled object 15 can be corrected by moving the material layer 3. it can. As described above, in the correction of the present embodiment, the transfer body 5 and the lamination stage 14 may be relatively moved so that the relative position between the transfer body 5 and the lamination stage 14 can be adjusted.

Further, the area sensor or the line sensor is used as the non-contact position sensor 8 to detect the position of the material layer 3 while the transfer body 5 is moving. However, the present invention is not limited to this, and an image sensor is used. The position of the material layer 3 may be detected while the transfer body 5 is stationary.
The stage correction mechanism 12 may include means for returning each motor to the origin position, and may have a function for returning each motor to the origin position after a necessary modeling operation is completed. Thereby, a new modeling operation can be started from the reference position of the stage correction mechanism 12.

As described above, according to the configuration of the modeling apparatus of the present embodiment, it is possible to suppress the positional deviation during modeling as much as possible by performing registration. Therefore, it becomes possible to form a high-quality shaped article with high shape accuracy and dimensional accuracy.
As a result, the time required for the secondary processing can be shortened even if secondary processing such as filing of the surface of the modeled object is required after modeling. This also leads to reduction of manual work, and further cost reduction is possible. Further, the present invention can be suitably applied even when a shape such as the inner surface of a modeled object that cannot be subjected to secondary processing is modeled.

(Other configuration examples of stage correction mechanism)
Here, another configuration example of the stage correction mechanism 12 is shown in FIGS. 9A and 9B.
The stage correction mechanism 12 shown in FIG. 9A includes a base 31 on which the model 15 is placed, a first axis drive mechanism 32, a second axis drive mechanism 33, and a rotary axis drive mechanism for adjusting the position of the base 31. 34. Here, the rotation shaft drive mechanism 34 is used for correcting the rotation direction around an axis perpendicular to the transfer surface of the transfer body. The second shaft drive mechanism 33 is used for correcting the transfer body conveyance direction. The first shaft drive mechanism 32 is used for correction in the direction perpendicular to the transport direction within the transport surface of the transfer body.
With this three-axis correction mechanism, the position of the material layer 3 on the transfer body and the position of the shaped article 15 stacked on the base 31 can be matched.

The stage correction mechanism 12 shown in FIG. 9B includes a base 35 on which the model 15 is placed, a first axis drive mechanism 36, a second axis drive mechanism 38, and a third axis drive for adjusting the position of the base 35. And a mechanism 37. Here, the third axis drive mechanism 37 is used for correcting the transfer direction of the transfer body. The first axis drive mechanism 36 and the second axis drive mechanism 38 are used for correction in the direction perpendicular to the conveyance direction within the transfer surface of the transfer body.
At the tip of each drive mechanism, a rotation shaft 39 that supports the base 35 rotatably is configured. When correcting in the conveyance direction of the transfer body 5, only the third axis drive mechanism 37 is moved. In order to correct the transfer body 5 in the direction orthogonal to the conveyance direction, the first axis drive mechanism 36 and the second axis drive mechanism 38 are moved by the same amount. Moreover, since the base 35 can be rotated by simultaneously driving the three-axis drive mechanism, the combination of the position of the material layer 3 on the transfer body 5 and the shaped article 15 on the base 35 can be obtained by this combination. The position can be adjusted.
Although the stage correction mechanism having a three-axis correction function has been described here, the number of correction axes can be reduced if accuracy can be suppressed on the mechanism.

[Example 2]
Example 2 will be described below. In the present embodiment, the different components from the first embodiment will be described, and the description of the same components as those in the first embodiment will be omitted.
FIG. 10 is a diagram illustrating a state in which the registration marker used in the present embodiment is transferred onto the transfer body 5.
In the first embodiment described above, registration markers are detected using a pair of opposing registration markers 402 and 403. On the other hand, in this embodiment, an example will be described in which a plurality of pairs of registration markers are used to detect the amount of positional deviation in the X direction, the Y direction, and the θ direction.

In this embodiment, a pair of opposing registration markers 801 and 802 similar to the registration markers 402 and 403 in FIG. 4 are used. Furthermore, a pair of opposing registration markers 803 and 804 having the same shape as the registration markers 801 and 802, each having a reverse triangular shape, are used. Further, a pair of opposing registration markers 805 and 806 similar to the pair of opposing registration markers 801 and 802 are used. A pair of opposing registration markers 807, 808 similar to the pair of opposing registration markers 803, 804 are used.

For the four pairs of registration markers in FIG. 10, Δθ, ΔX, ΔY can be calculated in the same manner as the method shown in FIGS. 5A to 5C, and the total positional deviation amount can be calculated from each result. Further, for the deviation in the Y direction, the positional deviation amount can be calculated using the same trigonometric ratio as in FIG. 5B for the markers arranged in the traveling direction (801 and 803, 805 and 807).
As a result, even when a part of the registration marker becomes undetectable, the correction amount can be calculated, and a correction amount robust to the shape accuracy of the marker itself can be obtained. .

[Example 3]
Example 3 will be described below. In the present embodiment, constituent parts different from those in the first and second embodiments will be described, and description of constituent parts similar to those in the first embodiment will be omitted.
FIG. 11 is a diagram illustrating a state in which the registration marker used in the present embodiment is transferred onto the transfer body 5.
In the first and second embodiments, an example in which a one-dimensional detection signal is acquired by a sensor having a circular or elliptical spot diameter is shown. On the other hand, in the present embodiment, an example in which the amount of deviation in the X direction, the Y direction, and the θ direction is detected using the line sensor 91 that can two-dimensionally scan the direction perpendicular to the transfer body conveyance direction. Indicates.

Reference numeral 901 denotes a registration marker, which is configured to fit a rectangle having a side parallel to the modeling area within the line width of the line sensor 91. The line sensor 91 scans the registration marker 901 two-dimensionally at a constant sampling interval.
In FIG. 11, S1, S2, and S3 are examples of signals when the positions L1, L2, and L3 on the registration marker 901 are scanned by the line sensor 91, respectively, and are referred to as cross-sectional profiles here.

  In the cross section at the position L1 of the registration marker 901, the signal S1 indicates a high level in a region where the registration marker 901 exists, and indicates a low level in a region where the registration marker 901 does not exist. Here, when a shift in the θ direction occurs in the registration marker 901, lines connecting points P1, P2, and P3 indicating edges of the registration marker in the respective cross-sectional profiles are skewed as shown in FIG. Therefore, the shift amount Δθ in the θ direction can be obtained using the shift amount of the edge on the cross-sectional profile and the sampling interval of the profile. Similarly to the second embodiment, the amount of deviation ΔX in the X direction is obtained from the position of the upper end of the registration marker 901 after correcting the deviation of Δθ, and the position in the Y direction is determined from the position of the lateral edge of the registration marker 901. A deviation amount ΔY can be obtained.

  According to the modeling apparatus of this embodiment, since the edge of the registration marker is reproduced from many cross-sectional shapes, registration that is robust to the modeling accuracy of the registration marker is possible.

[Example 4]
Example 4 will be described below. In the present embodiment, different components from those of the first to third embodiments will be described, and the description of the same components as those of the first to third embodiments will be omitted.
FIG. 12 is a cross-sectional view schematically showing a schematic configuration of the modeling apparatus of the present embodiment. In FIG. 12, the constituent elements denoted by reference numerals 41 to 57 and 61 have the same functions as the constituent elements denoted by reference numerals 1 to 17 and 21 in FIG.
In this embodiment, the stacking stage 54 is different from the above-described Embodiments 1 to 3 in that a linear motion stage 62 is provided in addition to the stage correction mechanism 52. The stacking stage 54 can be moved in the vertical direction by a stage vertical mechanism 53.
Since the operation of the stage up-and-down mechanism 53 is the same as that in the first embodiment until the material layer 43 on the transfer body is sandwiched with the transfer body 45 between the upper surface of the modeled object 55 and the opposing member 57, the material layer 43 is sandwiched. The operation after this will be described with reference to FIG.

  As shown in FIG. 12, after the material layer 43 is sandwiched between the upper surface of the modeled object 55 and the opposing member 57 together with the transfer body 5, the tangential speed of the transfer body 45 and the linear motion stage 62 is synchronized, It moves in the direction of arrow 63 shown in FIG. At that time, the stage correction mechanism 52 continues the correction in accordance with the displacement of the transfer body 45. The shift amount of the transfer body 45 is obtained by a sensor that detects an end face of the transfer body 45 (not shown). Even if conveyance of the transfer body 45 occurs due to this correction, the interface between the modeled object 55 and the transfer body 45 does not deviate, and a reliable lamination adhesive force can be ensured.

[Example 5]
Example 5 will be described. In the present embodiment, different components from those of the first to fourth embodiments will be described, and the description of the same components as those of the first to fourth embodiments will be omitted.
FIG. 13 is a cross-sectional view schematically showing a schematic configuration of the additive manufacturing apparatus of the present embodiment. In this embodiment, the non-contact type meandering sensor (transfer body end detector) 22 for measuring the belt end position in the direction orthogonal to the conveying direction of the transfer body 5 is provided near the upper portion of the stacking stage 14 in the first to the first embodiments. 4 and different.
In the correction control methods of Examples 1 to 4, correction is performed based on the positional deviation of the material layer detected by the non-contact sensor 8. For this reason, it is possible to correct the displacement of the material layer generated from the generation of the material layer to the position of the non-contact sensor 8, but to the position where the material layer adheres to the laminate 15 from the non-contact sensor 8. It is not possible to correct a conveyance error (conveyance deviation) applied to the. On the other hand, in the present embodiment, it is possible to correct a positional deviation including a conveyance error from the non-contact sensor 8 to the stacking position.

The flow of the correction process in the present embodiment will be described using the example of the flowchart of the correction process shown in FIG.
In step S1501, the image generation control unit 201 transfers the registration marker to the transfer body 5. This is the same step as step S301 in FIG. The registration marker on the transfer body 5 is detected by the non-contact sensor 8 by the correction control unit 204 in step S1502, and the tip position and passage distance of the registration marker are stored. In subsequent step S1503, the amount of displacement in the X direction, Y direction, and θ direction of the material layer is calculated from the detection result in step S1502.

In step S <b> 1504, the correction control unit 204 measures the end position in the direction orthogonal to the transfer direction of the transfer body 5 by the non-contact meandering sensor 22. In step S1505, the material layer reaches the stacking position from the time when the registration marker is detected in step S1502 from the detection result of the end position of the transfer body 5 obtained in step S1504 by the correction control unit 204. The amount of change in the Y direction and θ direction of the transfer body 5 up to the time is calculated.
In step S1506, the correction control unit 204 calculates the correction amount by superimposing the material layer positional deviation amount calculated in step S1503 and the variation amount of the transfer body 5 calculated in step S1505. In step S1507, the stacking stage 14 is controlled by the correction control unit 204 so as to correct the positional deviation corresponding to the positional deviation amount in the three directions calculated in step S1506. And the lamination | stacking control part 202 moves the lamination | stacking stage 14 up and down, and the molded article 1
A material layer 3 is laminated on 5.

FIG. 15 is a diagram illustrating an example of a method for measuring the end portion of the transfer body 5 in the present embodiment, and is a view in which the lower surface of the transfer body 5 is viewed from the lower side in the vertical direction and from the direction of the stacking stage 14. In FIG. 15, the state where the transfer body 5 is meandering is indicated by a solid line 1601, and the state where the transfer body 5 is not meandering is indicated by a dotted line 1602.
In this embodiment, the non-contact meandering sensor 22 is a transmissive line sensor and measures the end position of the transfer body 5 in the vicinity of the stacking position. Reference numeral 1606 denotes a detection position by the non-contact sensor 8, and 1607 denotes a position detected by the non-contact meandering sensor 22.

  In FIG. 15, the transfer body 5 from the position of the dotted line 1602 to the solid line from the time when the registration marker is detected by the non-contact sensors 8-1 and 8-2 to the time when the material layer 3 reaches the stacking position 1607. Suppose that it moved to the position 1601. During this time, the difference ΔYb between the end positions of 1601 and 1602 measured by the non-contact type meandering sensor 22 is added to the stacking position 1607 after the material layer 3 is detected by the non-contact type sensor 8. This is a transport error in a direction orthogonal to the direction. Further, the transport error Δθb in the rotation direction can be obtained by using the distance Lb by which the material layer 3 detected in 1606 moves until it is detected in 1607 and ΔYb. The correction control unit 204 performs correction processing by adding ΔYb and Δθb obtained in this embodiment to ΔY and Δθ obtained from the registration marker by the method of FIG.

  According to the present embodiment, in addition to the positional deviation that occurs between the generation of the material layer 3 and the position of the non-contact type sensor 8, the conveyance error that occurs between the non-contact type sensor 8 and the stacking position of the material layer 3 also occurs. It can correct | amend and it becomes possible to produce | generate a highly accurate molded article.

  DESCRIPTION OF SYMBOLS 2 ... Image formation part, 3 ... Material layer, 5 ... Transfer body, 6 ... Material layer, 8 ... Non-contact position sensor, 12 ... Stage correction mechanism, 14 ... Laminated stage, 16 ... Control part

Claims (10)

Based on the given data, a material layer forming unit that forms a material layer made of modeling material,
A transfer body that conveys the material layer transferred from the material layer forming section;
A stage on which the material layer conveyed by the transfer body is laminated;
A modeling apparatus for producing a three-dimensional object made of the modeling material on the stage,
A detection unit for detecting the position of the material layer on the transfer body;
A measurement unit that measures the amount of positional deviation of the material layer on the transfer body from the detection result of the detection unit;
Based on the amount of misalignment measured by the measuring unit, the stage is moved in a direction perpendicular to the stacking direction of the material layers and in a rotation direction centered on an axis whose axial direction is the stacking direction of the material layers. An adjustment unit capable of moving and adjusting a relative position between the transfer body and the stage;
A modeling apparatus comprising: An addition unit for adding registration marker data to the data to be given to the material layer forming unit,
The modeling apparatus according to claim 1, wherein the detection unit is provided at a position corresponding to the registration marker and detects a position of the registration marker. The registration marker has a first edge arranged so as to be orthogonal to the moving direction of the transfer body and a second edge arranged so as to be inclined with respect to the moving direction of the transfer body. Shape,
The measurement unit obtains the position of the material layer in the traveling direction of the transfer body from the detection timing of the first edge, and the difference between the detection timing of the first edge and the detection timing of the second edge From the above, obtain the amount of positional deviation of the material layer with respect to the direction orthogonal to the traveling direction of the transfer body,
Furthermore, two registration markers are arranged side by side in a direction orthogonal to the traveling direction of the transfer body,
The measurement unit detects a positional deviation amount of the material layer with respect to a rotation direction about an axis orthogonal to a transfer surface of the transfer body onto which the material layer is transferred, based on a difference between detection timings of the two first edges. The modeling apparatus according to claim 2, wherein:   The modeling apparatus according to claim 2, wherein the measurement unit performs a noise removal process of removing a noise component from a registration marker signal detected by the detection unit.   The adjustment unit is configured to stack the material layer on the transfer body on the stage, the transfer body when the material layer one layer before the material layer is stacked on the stage, and the stage. The relative position between the transfer body and the stage is adjusted based on the difference between the positional deviation amount of the material layer and the positional deviation amount of the previous material layer with reference to the relative position between The modeling apparatus according to any one of claims 1 to 4, wherein:   When the value obtained by measuring the positional deviation amount of the material layer by the measurement unit is a value exceeding the set range, the adjustment unit is configured to 1 of the material layer when the material layer is stacked on the stage. The modeling apparatus according to claim 1, wherein a relative position between the transfer body and the stage when the material layer before the layer is stacked on the stage is maintained. .   The modeling apparatus according to any one of claims 1 to 6, further comprising meandering adjusting means for adjusting the meandering of the transfer body. In the vicinity of the laminating position where the material layer is laminated on the stage, it has a transfer body end detection unit that detects the end position of the transfer body,
The measurement unit calculates a transfer deviation amount of the transfer body in the plane of the transfer body, which occurs from the detection unit to the stacking position, from the detection result of the transfer body end detection unit,
The adjustment unit adjusts the relative position between the transfer body and the stage by adding the positional deviation amount of the material layer acquired by the measurement unit and the conveyance deviation amount of the transfer body. The additive manufacturing apparatus according to any one of claims 1 to 6. Origin detecting means for detecting the origin position of the stage;
Storage means for storing the movement amount of the origin position of the stage relative to the reference position of the modeling apparatus main body,
9. The modeling apparatus according to claim 1, wherein the adjustment unit returns the stage to the reference position after completion of the operation of producing a three-dimensional object. Based on the given data, a material layer forming unit that forms a material layer made of modeling material,
A transfer body that conveys the material layer transferred from the material layer forming section;
A stage on which the material layer conveyed by the transfer body is laminated;
A modeling method using a modeling apparatus for producing a three-dimensional object made of the modeling material on the stage,
A step of adding registration marker data to data given to the material layer forming portion;
Detecting the registration marker included in the material layer on the transfer body with a detection unit;
A step of measuring a displacement amount of the material layer on the transfer body from a detection result of the detection unit by a measurement unit;
Based on the amount of misalignment measured by the measuring unit, the stage is moved in a direction perpendicular to the stacking direction of the material layers and in a rotation direction centered on an axis whose axial direction is the stacking direction of the material layers. Moving and adjusting the relative position between the transfer body and the stage;
A modeling method comprising: