JP2019107698A - 付加製造のための位置フィードバックを提供するシステムおよび方法 - Google Patents
付加製造のための位置フィードバックを提供するシステムおよび方法 Download PDFInfo
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Abstract
Description
本米国特許出願は、参照のためその内容全体を本明細書に援用する2017年12月19日出願の米国特許出願第62/607,598号明細書からの優先権および便宜を主張する。
12 フレーム
14 ロボット
16 テーブル
22 ワークピース
26 ドア
32 窓
40 制御パネル
42 制御筐体
60 銃
61 絶縁型導電管
62 導管
63 電極導管
64 電極ワイヤ
65 ガス拡散器
66 コンテナ
67 コンタクトチップ
68 ワイヤフィーダ
72 電源
74 プラットホーム
76 ロボットコントローラ
105 スイッチング電源
110 電力変換回路
120 波形生成器
130 コントローラ
140 電圧帰還回路
150 電圧帰還回路
180 ブリッジスイッチング回路
500 グラフ
510 プロット
520 プロット
600 グラフ
610 面プロット
611 アンペア数/WFSパラメータ対
612 CTWD値
700 コントローラの一部
710 LUT
711 入力
712 CTWD
800 コントローラの一部
810 平均化モジュール
812 平均CTWD
820 補正係数モジュール
822 プロセス持続時間
824 WFS
900 方法
910 工程
920 工程
930 工程
940 工程
1100 コントローラの一部
1110 比較器
1120 第1のLUT
1130 第2のLUT
1140 第3のLUT
1200 レーザ
1210 ビーム
A 角度
CTWD コンタクトチップツーワーク距離
LUT ルックアップテーブル
Z 距離
WFS ワイヤ送り速度
Claims (28)
- 電源と;
銃のコンタクトチップを介し3Dワークピース部分へ付加的材料を供給する材料フィーダを含む付加製造システムであって、前記電源は、
瞬間的パラメータ対をサンプリングし、ここで、前記瞬間的パラメータ対の各瞬間的パラメータ対は、前記3Dワークピース部分の現在層を生成する間のロボット付加製造プロセス中に、前記3Dワークピース部分へ前記付加的材料を供給するワイヤのワイヤ送り速度、前記電源の出力電力、および前記電源の出力回路インピーダンスを含むグループから選択される任意の2つのパラメータを含み;
前記現在層の前記生成中に前記瞬間的パラメータ対の各パラメータ対がサンプリングされると、各パラメータ対の前記ロボット付加製造プロセス中の瞬間的コンタクトチップツーワーク距離を少なくとも各パラメータ対に基づき判断し;
各瞬間的コンタクトチップツーワーク距離が現在層の前記生成中に判断されると移動平均コンタクトチップツーワーク距離を各瞬間的コンタクトチップツーワーク距離に基づき判断し;
前記現在層の所望蒸着レベルからの蒸着レベルの逸脱を補償するために前記3Dワークピース部分の現在層を生成する間に使用される補正係数を少なくとも前記移動平均コンタクトチップツーワーク距離に基づき生成するように構成される、付加製造システム。 - 前記2つのパラメータは、ワイヤ送り速度である第1のパラメータと、前記電源の前記出力電力または前記電源の前記出力回路インピーダンスである第2のパラメータとを含む、請求項1に記載の付加製造システム。
- 前記ロボット付加製造プロセスは前記ワイヤを使用するホットワイヤプロセスを含む、請求項1に記載の付加製造システム。
- 前記電源は高エネルギー熱源を含み、前記3Dワークピース部分の前記現在層の前記生成は、パドルを生成するために十分なエネルギー密度を前記3Dワークピース部分へ提供する工程を含み、前記ワイヤは前記現在層の前記生成中に前記パドルに入る、請求項3に記載の付加製造システム。
- 前記ワイヤが前記パドルの表面に対して前記パドルに入る時の前記ワイヤの中心線の角度は10°〜75°の範囲内である、請求項4に記載の付加製造システム。
- 前記瞬間的コンタクトチップツーワーク距離はさらに、前記ロボット付加製造プロセス中に使用されるホットワイヤのタイプ、ホットワイヤ径、蒸着プロセス、または遮蔽ガスのうちの少なくとも1つに基づく、請求項2に記載の付加製造システム。
- 前記移動平均コンタクトチップツーワーク距離は、前記瞬間的コンタクトチップツーワーク距離の単純数学的移動平均、または前記瞬間的コンタクトチップツーワーク距離の重み付け移動平均の1つである、請求項1に記載の付加製造システム。
- 前記電源はさらに:
前記移動平均コンタクトチップツーワーク距離と設定点コンタクトチップツーワーク距離とを比較することに少なくとも部分的により前記補正係数を生成し;
前記補正係数に応じて前記現在層の生成中に移動速度、持続時間、または前記ワイヤ送り速度のうちの少なくとも1つを調整するように構成される、請求項1に記載の付加製造システム。 - 前記補正係数に応じて前記移動速度を前記調整する工程は事前設定移動速度を考慮する工程を含み;
前記補正係数に応じて前記持続時間を前記調整する工程は事前設定持続時間を考慮する工程を含み;
前記補正係数に応じて前記ワイヤ送り速度を前記調整する工程は事前設定ワイヤ送り速度を考慮する工程を含む、請求項8に記載の付加製造システム。 - 前記補正係数はさらに、前記3Dワークピース部分に対応する少なくとも1つの3Dモデルパラメータ、または前記現在層の現在作業のためにロボットコントローラにより提供される少なくとも1つのロボットパラメータに基づく、請求項1に記載の付加製造システム。
- 前記少なくとも1つの3Dモデルパラメータは前記現在層の指定高さを含み、前記少なくとも1つのロボットパラメータは前記現在層の前記銃の指定位置を含む、請求項10に記載の付加製造システム。
- 前記電源と作動可能に通信するように構成されたロボットコントローラを有するロボットをさらに含む請求項1に記載の付加製造システム。
- 前記銃は前記ロボットへ作動可能に接続される、請求項12に記載の付加製造システム。
- 前記銃および前記電源へ作動可能に接続されたワイヤフィーダをさらに含む請求項13に記載の付加製造システム。
- 前記電源はさらに:
現在層全体に関して判断された各瞬間的コンタクトチップツーワーク距離に基づき全平均コンタクトチップツーワーク距離を判断し;
前記移動平均コンタクトチップツーワーク距離に応じて前記現在層の生成中に前記付加製造システムの蒸着持続時間、移動速度、またはワイヤ送り速度のうちの少なくとも1つを調整し;
少なくとも前記全平均コンタクトチップツーワーク距離に基づき、前記3Dワークピース部分の次層を生成する際に使用される補正係数を生成するように構成される、請求項1に記載の付加製造システム。 - 前記電源はコントローラを含み、前記コントローラは:
前記瞬間的コンタクトチップツーワーク距離を判断し;
前記移動平均コンタクトチップツーワーク距離を判断し;
前記全平均コンタクトチップツーワーク距離を判断し;
前記現在層の前記生成中に前記蒸着持続時間、前記移動速度、または前記ワイヤ送り速度のうちの少なくとも1つを調整し;
前記次層を生成する際に使用される前記補正係数を生成するように構成される、請求項15に記載の付加製造システム。 - 電源と、銃のコンタクトチップを介し3Dワークピース部分へ付加的材料を供給する材料フィーダとを使用する付加製造方法において、
瞬間的パラメータ対をサンプリングする工程であって、前記瞬間的パラメータ対の各瞬間的パラメータ対は、前記3Dワークピース部分の現在層を生成する間のロボット付加製造プロセス中に、前記3Dワークピース部分へ前記付加的材料を供給するワイヤのワイヤ送り速度、前記電源の出力電力、および前記電源の出力回路インピーダンスを含むグループから選択された任意の2つのパラメータを含む、工程と;
前記現在層の前記生成中に前記瞬間的パラメータ対の各パラメータ対がサンプリングされると、各パラメータ対の前記ロボット付加製造プロセス中の瞬間的コンタクトチップツーワーク距離を少なくとも各パラメータ対に基づき判断する工程と;
各瞬間的コンタクトチップツーワーク距離が現在層の前記生成中に判断されると移動平均コンタクトチップツーワーク距離を各瞬間的コンタクトチップツーワーク距離に基づき判断する工程と;
前記現在層の所望蒸着レベルからの蒸着レベルの逸脱を補償するために前記3Dワークピース部分の現在層を生成する間に使用される補正係数を少なくとも前記移動平均コンタクトチップツーワーク距離に基づき生成する工程と、を含む方法。 - 前記2つのパラメータは、ワイヤ送り速度である第1のパラメータと、前記電源の前記出力電力または前記電源の前記出力回路インピーダンスである第2のパラメータとを含む、請求項17に記載の方法。
- 前記ロボット付加製造プロセスは前記ワイヤを使用するホットワイヤプロセスを含む、請求項17に記載の方法。
- 前記3Dワークピース部分の前記現在層を生成する前記工程は、パドルを生成するために十分なエネルギー密度を高エネルギービームから前記3Dワークピース部分へ提供する工程を含み、前記ワイヤは前記現在層の前記生成中に前記パドルに入る、請求項19に記載の方法。
- 前記ワイヤが前記パドルの表面に対して前記パドルに入る時の前記ワイヤの中心線の角度は10°〜75°の範囲内である、請求項20に記載の方法。
- 前記瞬間的コンタクトチップツーワーク距離はさらに、前記ロボット付加製造プロセス中に使用されるホットワイヤのタイプ、ホットワイヤ径、蒸着プロセス、または遮蔽ガスのうちの少なくとも1つに基づく、請求項18に記載の方法。
- 前記移動平均コンタクトチップツーワーク距離は、前記瞬間的コンタクトチップツーワーク距離の単純数学的移動平均、または前記瞬間的コンタクトチップツーワーク距離の重み付け移動平均の1つである、請求項17に記載の方法。
- 前記移動平均コンタクトチップツーワーク距離と設定点コンタクトチップツーワーク距離とを比較する工程により少なくとも部分的に前記補正係数を生成する工程と;
前記補正係数に応じて前記現在層の生成中に移動速度、持続時間、また前記ワイヤ送り速度のうちの少なくとも1つを調整する工程と、をさらに含む請求項17に記載の方法。 - 前記補正係数に応じて前記移動速度を調整する前記工程は事前設定移動速度を考慮する工程を含み;
前記補正係数に応じて前記持続時間を調整する前記工程は事前設定持続時間を考慮する工程を含み;
前記補正係数に応じて前記ワイヤ送り速度を調整する前記工程は事前設定ワイヤ送り速度を考慮する工程を含む、請求項24に記載の方法。 - 前記補正係数はさらに、前記3Dワークピース部分に対応する少なくとも1つの3Dモデルパラメータ、または前記現在層の現在作業のためにロボットコントローラにより提供される少なくとも1つのロボットパラメータに基づく、請求項17に記載の方法。
- 前記少なくとも1つの3Dモデルパラメータは前記現在層の指定高さを含み、前記少なくとも1つのロボットパラメータは前記現在層の前記銃の指定位置を含む、請求項26に記載の方法。
- 現在層全体に関して判断された各瞬間的コンタクトチップツーワーク距離に基づき全平均コンタクトチップツーワーク距離を判断する工程と;
前記移動平均コンタクトチップツーワーク距離に応じて前記現在層の生成中に蒸着持続時間、移動速度、または前記ワイヤ送り速度のうちの少なくとも1つを調整する工程と;
少なくとも前記全平均コンタクトチップツーワーク距離に基づき、前記3Dワークピース部分の次層を生成する際に使用される補正係数を生成する工程と、をさらに含む請求項17に記載の方法。
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