JP2020192584A - Shaped-object manufacturing method, lamination control apparatus, and program - Google Patents

Abstract

To inhibit beads from being formed poorly due to defective generation of arc when a shaped object is manufactured which comprises a laminate of beads made by fusing and solidifying a filler material using arc.SOLUTION: A control device 30 causes a laminatedly shaped object 120 in which is laminated a plurality of beads 121 to be formed on a base material 110 on the basis of output data including drawn-layer shape data representing the shape of the laminate. The control device 30, after causing a first layer of beads 121 to be formed from a start point to an end point on the basis of the drawn-layer shape data of the first layer, causes a slag-free non-deposited portion to be detected from the first layer of formed beads 121 to make a modification using the detected non-deposited portion as a start point of a second layer of drawn-layer shape data, and then a second layer of beads 121 to be formed from a start point to an end point on the basis of the second layer of modified drawn-layer shape data.SELECTED DRAWING: Figure 1

Description

The present invention relates to a method for manufacturing a modeled object, a stacking control device, and a program.

In recent years, the needs for 3D printers as a means of production have been increasing, and research and development have been carried out for practical use in the aircraft industry and the like, especially for application to metal materials. A 3D printer made of a metal material uses a heat source such as a laser or an arc to melt a metal powder or a metal wire, and laminate the molten metal to form a modeled object.

For example, Patent Document 1 describes a step of generating shape data expressing the shape of a mold, a step of dividing a mold into laminates along contour lines based on the generated shape data, and the obtained lamination. A method for manufacturing a mold including a step of creating a moving path of a welding torch for supplying a filler material based on body shape data is described.

Japanese Patent No. 3784539

Here, in the case of manufacturing a modeled product including a laminated body in which a plurality of beads formed by melting and solidifying a filler metal using an arc are manufactured, a step of generating an arc each time a bead is formed (arc start). Is required.
However, when the next bead is to be formed on the already formed bead, slag is attached to the surface of the already formed bead as the filler metal is melted and solidified. There is. Since the slag is usually composed of an insulator, it is difficult to generate an arc at the portion where the slag is attached, and as a result, a bead formation failure due to a poor arc generation may occur. It was.

INDUSTRIAL APPLICABILITY The present invention suppresses the occurrence of bead formation defects due to arc generation defects when producing a modeled object including a laminated body in which a plurality of beads formed by melting and solidifying a filler metal are laminated using an arc. The purpose is to do.

For this purpose, the present invention manufactures a modeled object including a laminated body in which a plurality of beads formed by melting and solidifying a filler metal by using an arc are produced based on three-dimensional shape data. The method is a step of determining a division point of each layer from slice data obtained by dividing the three-dimensional shape data into a plurality of layers, a start point formed by extending one end side of the division point, and the division. A step of modifying the slice data by setting an end point formed by extending the other end side of the point and adding the start point and the end point, and from the start point to the end point based on the corrected slice data. It has a step of manufacturing the modeled object by forming the bead toward it, and in the step of manufacturing, the bead that has already been formed is stretched by adding the start point and the end point. Provided is a method for producing a modeled object, in which a non-adhered portion to which slag is not attached is identified from the stretched region, and the non-adhered portion is corrected to the starting point to form the next bead.
Here, the non-attached portion may be specified by extracting the region to which the slag is attached from the image obtained by capturing the surface of the bead that has already been formed.
Further, the step of removing the slag adhering to the bead by abutting the filler material or the welding torch holding the filler metal against the already formed bead may be further included.

Further, the present invention is a method for manufacturing a modeled object, which comprises producing a modeled object including a laminated body in which a plurality of beads formed by melting and solidifying a filler metal using an arc are used based on three-dimensional shape data. , A step of receiving output data in which a division point is set for each layer of slice data obtained by dividing the three-dimensional shape data into a plurality of layers, and an xth layer (x is 2) of the received output data. Based on the above data), the step of forming the bead of the xth layer from the start point to the end point, with one end side of the division point as the start point and the other end side of the division point as the end point, and formation. The step of detecting the non-adhered portion to which the slag is not attached from the bead of the x-th layer, and x + 1 of the output data so that the non-adhered portion of the bead of the x-th layer becomes the starting point. Provided is a method for manufacturing a modeled object, which comprises a step of modifying the data of the layer and a step of forming a bead of the x + 1 layer on the bead of the x + 1 layer based on the modified data of the x + 1 layer. ..
Here, in the accepting step, the output data to which a new start point formed by extending the start point and a new end point formed by extending the end point is added is received, and in the detecting step, the formed x Among the beads of the layer, the non-adhered portion may be detected from the stretched region stretched by adding the new start point and the new end point.
Further, in the detection step, the non-adhered portion may be detected by using an image obtained by capturing the formed bead of the xth layer.

Further, the present invention provides a receiving means for receiving output data in which division points are set in each layer of slice data obtained by dividing three-dimensional shape data representing the shape of a three-dimensional model into a plurality of layers. Based on the data of the xth layer (x is an integer of 2 or more) in the output data, one end side of the division point is set as a start point, the other end side of the division point is set as an end point, and the start point is changed to the end point. The first output means for outputting an instruction for forming the bead of the x-th layer and the non-adhered portion to which the slag is not attached detected from the formed bead of the x-th layer are set as the starting points. An instruction for forming a bead of the x + 1 layer on the bead of the x + 1 layer based on the correction means for modifying the data of the x + 1 layer of the output data and the modified data of the x + 1 layer. Provided is a stacking control device for a modeled object including a second output means for outputting the data.

Furthermore, the present invention has a function of receiving output data in which division points are set in each layer of slice data obtained by dividing three-dimensional shape data representing the shape of a three-dimensional modeled object into a plurality of layers on a computer. Based on the data of the xth layer (x is an integer of 2 or more) of the received output data, the start point is one end side of the division point and the other end side of the division point is the end point. The function of outputting an instruction for forming the bead of the x-th layer toward the end point and the non-adhered portion where the slag is not attached detected from the bead of the x-th layer formed becomes the start point. In the function of modifying the data of the x + 1 layer of the output data, and an instruction for forming the bead of the x + 1 layer on the bead of the x + 1 layer based on the modified data of the x + 1 layer. Provide a program to realize the output function.

According to the present invention, when a modeled product including a laminated body in which a plurality of beads formed by melting and solidifying a filler metal is melted and solidified by using an arc is manufactured, a bead formation defect occurs due to an arc generation defect. Can be suppressed.

It is a figure which showed the schematic structure example of the metal laminated modeling system in embodiment of this invention. It is a perspective view which showed the schematic structure of the robot device. It is a figure which showed the functional configuration example of a control device. It is a figure which showed the hardware configuration example of the planning apparatus. It is a figure which showed the functional configuration example of a plan making apparatus. It is a flowchart which showed the operation example of the plan making apparatus. It is a flowchart which showed the operation example of the laminated modeling apparatus. (A) to (d) are diagrams for explaining the concept of various data used in the planning apparatus. (A) to (c) are diagrams (continued) for explaining the concept of various data used in the planning apparatus. It is a figure for demonstrating various paths in the stretched layer shape data. (A) to (d) are diagrams showing an example of a manufacturing process of a structure. (A) to (d) are diagrams showing an example of a procedure for laminating the beads of the first layer and the second layer in the manufacturing process of the structure. It is a figure which shows another example of the laminated model | manufacturing | manufacturing thing manufactured by the manufacturing method of this embodiment.

Hereinafter, embodiments of the present invention will be described in detail with reference to the accompanying drawings.
[Metal lamination modeling system]
FIG. 1 is a diagram showing a schematic configuration example of a metal laminated molding system 1 according to an embodiment of the present invention.
The metal laminated modeling system 1 of the present embodiment includes a planning device 40 and a laminated modeling device 60. Of these, the plan creation device 40 creates a control program or the like related to a plan (hereinafter, referred to as a stacking plan) for forming the laminated model 120 by sequentially stacking the beads 121. Further, the laminated modeling device 60 forms a laminated model 120 on the base material 110 by operating according to a control program related to the stacking plan created by the plan creation device 40, and has the base material 110 and the laminated model 120. The structure 100 is manufactured. The laminated modeling device 60 includes a robot device 10, a welding torch 20, a camera 25, and a control device 30. In the metal laminated modeling system 1, the planning creation device 40 writes a control program or the like for controlling the laminated modeling device 60 on a removable recording medium 50 such as various memory cards. Then, the control device 30 provided in the laminated modeling device 60 reads out and executes the control program or the like written in the recording medium 50.

Further, a CAD (Computer Aided Design) device 2 is connected to the planning device 40 provided in the metal laminated modeling system 1. This CAD device 2 has a function of designing a modeled object in three-dimensional coordinates using a computer and holding three-dimensional data (hereinafter, referred to as "three-dimensional CAD data") obtained by the design. have. Although the description is made here assuming that the CAD device 2 is installed outside the metal laminated modeling system 1, the CAD device 2 may be provided inside the metal laminated modeling system 1.

Next, each of the laminated modeling device 60 and the planning creation device 40 constituting the metal laminated modeling system 1 will be described.
(Laminate modeling equipment)
The laminated modeling device 60 used in the present embodiment is a diversion of a robot welding device that employs a gas shielded arc welding method. The laminated modeling device 60 is attached to a robot device 10 composed of a so-called industrial robot, a welding torch 20 attached to the robot device 10 to supply wires 21 used in the welding process, and the robot device 10. It has a camera 25 that captures an image of the periphery of the welding torch 20, and a control device 30 that controls the operations of the robot device 10, the welding torch 20, and the camera 25. In addition to this, the laminated modeling device 60 further includes a gas supply device for supplying shield gas, a wire supply device for supplying wires 21, and the like, but detailed description thereof will be omitted here. ..

[Robot device]
FIG. 2 is a perspective view showing a schematic configuration of a robot device 10 provided in the laminated modeling device 60. Hereinafter, the configuration of the robot device 10 will be described with reference to FIG. 2 in addition to FIG.

The robot device 10 of the present embodiment is a 6-axis vertical articulated robot having 6 general drive axes. However, the robot device 10 is not limited to the vertical articulated robot, and may have other configurations. Further, even when the robot device 10 employs a vertical articulated robot, the number of axes is not limited to 6 axes, and may be 5 axes or less, or 7 axes or more. It doesn't matter.

The robot device 10 includes a base 11 fixed to an installation target such as a floor, a swivel portion 12 provided on the base 11 so as to be swivel around a first drive shaft S1 along the vertical direction, and a horizontal direction. One end portion is connected to the swivel portion 12 via the second drive shaft S2, and the lower arm portion 13 that can rotate around the second drive shaft S2 is provided. Further, the robot device 10 is provided on the upper arm portion 14 connected to the other end of the lower arm portion 13 via a third drive shaft S3 parallel to the second drive shaft S2, and the fourth drive portion 14. A wrist swivel portion 15 that can be rotated around the arm axis by the shaft S4 is provided. Further, the robot device 10 has a wrist bending portion 16 connected to the wrist turning portion 15 via the fifth drive shaft S5, and a wrist rotating portion connected to the tip of the wrist bending portion 16 via the sixth drive shaft S6. It is equipped with 17. In the robot device 10, the lower arm portion 13, the upper arm portion 14, the wrist turning portion 15, the wrist bending portion 16, and the wrist rotating portion 17 constitute an articulated arm.

A holding portion 18 for holding the welding torch 20 and the camera 25 is attached to the wrist rotating portion 17, which is the most advanced axis of the articulated arm, by functioning as a so-called end effector.

[Welding torch]
The welding torch 20 has a substantially tubular shield nozzle to which a shield gas such as argon gas or carbon dioxide gas is supplied, and a contact tip (both not shown) arranged inside the shield nozzle. Then, the wire 21 to be fed is held in the contact tip. The welding torch 20 forms and laminates a plurality of beads 121 on the base metal 110 by generating an arc while feeding the wire 21 and melting and solidifying the wire 21 while flowing a shield gas. The model 120 is formed. In the metal laminated modeling system 1 of the present embodiment, the wire 21 as an example of the filler metal used for forming the laminated model 120 is determined according to the functions and characteristics required for the laminated model 120. , Can be selected as appropriate. Here, the description will be given by taking as an example a "welding type" in which the wire 21 itself is an electrode and a filler material, but a "non-melting type" can also be adopted.

〔camera〕
The camera 25 has an imaging device such as a CCD or CMOS, and in this example, it can capture an infrared image. The camera 25 is held together with the welding torch 20 by a holding portion 18 attached to the wrist rotating portion 17 located at the forefront of the robot device 10, and moves following the welding torch 20 to cause the welding torch. An image (infrared image) of the periphery of the tip of the wire 21 protruding from 20 is taken.

〔Control device〕
FIG. 3 is a diagram showing a functional configuration example of the control device 30 provided in the laminated modeling device 60. Hereinafter, the configuration of the control device 30 will be described with reference to FIG. 3 in addition to FIG.

The control device 30 of the present embodiment includes a reception unit 301, an overall control unit 302, a robot control unit 303, a welding control unit 304, and a camera control unit 305.

{Reception Department}
The reception unit 301 inputs output data including a control program for operating the robot device 10 and the welding torch 20 constituting the laminated modeling device 60 in conjunction with each other from the plan creation device 40 via the recording medium 50. Accept.

{Overall control unit}
The overall control unit 302 as an example of the first output means, the correction means, and the second output means is for operating the robot device 10 and the welding torch 20 in conjunction with each other according to the control program received by the reception unit 301. Control.

{Robot control unit}
The robot control unit 303 performs position control, attitude control, and the like of the welding torch 20 held by the holding unit 18 by operating each unit constituting the robot device 10 under the control of the overall control unit 302.

{Welding control unit}
The welding control unit 304 controls the welding torch 20, the power feeding operation, the wire feeding operation, the gas supply operation, and the like under the control of the overall control unit 302.

{Camera control unit}
The camera control unit 305 controls the shooting operation by the camera 25 under the control of the overall control unit 302.

(Planning device)
Subsequently, the details of the plan creation device 40 will be described.

[Hardware configuration]
FIG. 4 is a diagram showing a hardware configuration example of the planning apparatus 40 according to the present embodiment.
The planning device 40 of the present embodiment is realized by, for example, a general-purpose PC (Personal Computer) or the like. Although not specifically described, the control device 30 provided in the laminated modeling device 60 also has the same hardware configuration as the planning device 40 described below.

The plan creation device 40 has a CPU (Central Processing Unit) 41 that reads and executes programs such as an OS and various applications, and a ROM (Read) that stores programs executed by the CPU 41 and data used when executing the programs. It includes a Only Memory) 42 and a RAM (Random Access Memory) 43 that stores data and the like that are temporarily generated when the program is executed. Further, the plan creation device 40 is located between an HDD (Hard Disk Drive) 44 that stores various programs, various data, and the like, and devices such as a CAD device 2 and a control device 30 provided outside the plan creation device 40. It further includes a NIC (Network Interface Card) 45 for transmitting and receiving data, an input device 46 for receiving input from an operator, a display device 47 for displaying an image on a display screen, and a bus 48 for connecting them. .. The program executed by the CPU 41 provided in the plan creation device 40 is stored in the ROM 42 or the HDD 44 in advance, stored in a storage medium such as a CD-ROM, or provided to the CPU 41. It is also possible to provide the CPU 41 via a network (not shown).

[Functional configuration]
FIG. 5 is a diagram showing a functional configuration example of the plan creation device 40 of the present embodiment.
The plan creation device 40 of the present embodiment includes an acquisition unit 401, a conversion unit 402, a cutting unit 403, a division unit 404, an extension unit 405, a creation unit 406, an addition unit 407, and an output unit 408. have. Hereinafter, the configuration of the planning apparatus 40 will be described with reference to FIG. 4 in addition to FIG.

{Acquisition part}
The acquisition unit 401 acquires the three-dimensional CAD data D3d of the modeled object that is the basis of the laminated modeled object 120 (see also FIG. 8A described later) from the CAD device 2. Here, the three-dimensional CAD data D3d is an example of three-dimensional shape data.

{Conversion part}
The conversion unit 402 converts the three-dimensional CAD data D3d received from the acquisition unit 401 into the internal data Di used for various data processing in the plan creation device 40.

{Cut part}
The cutting unit 403 cuts (slices) the internal data Di received from the conversion unit 402 so as to form a laminated body of a plurality of layers, so that the layer shape data Ds (specifically, the layer shape of the first layer) is formed. Data for n layers including the layer shape data Ds (n) of the data Ds (1) to the nth layer: See also FIG. 8 (b) described later) is created. Here, the layer shape data Ds is an example of slice data.

{Division}
The division unit 404 sets a division point for each layer with respect to the layer shape data Ds received from the cutting unit 403, thereby setting the divided layer shape data Dd (specifically, the divided layer shape data of the first layer). Data for n layers including the divided layer shape data Dd (n) of the Dd (1) to nth layers: see also FIG. 8 (c) described later) is created. Here, the divided layer shape data Dd is an example of the modified slice data.

{Stretched part}
The stretched portion 405 adds a start point and an end point to each layer to the split layer shape data Dd received from the split section 404, whereby the stretched layer shape data De (specifically, the first layer has been stretched). Data for n layers including the stretched layer shape data De (n) of the layer shape data De (1) to the nth layer: also referred to FIG. 8 (d) described later) is created. Here, the stretched layer shape data De is an example of the modified slice data.

{Creation department}
The creating unit 406 uses the control data Dc used in the control program executed by the control device 30 of the laminated modeling device 60 when manufacturing the laminated model 120 based on the stretched layer shape data De created by the stretched unit 405. To create.

{Additional part}
The addition unit 407 creates output data Do by adding the stretched layer shape data De received from the stretching unit 405 and the control data Dc received from the creating unit 406 to the control program executed by the control device 30. To do.

{Output section}
The output unit 408 outputs the output data Do received from the addition unit 407 by writing it on the recording medium 50.

[Structure]
Here, the structure 100 manufactured by the metal laminated modeling system 1 of the present embodiment will be described with reference to FIG. 1 and the like.
The structure 100 of the present embodiment includes a base material 110 to be laminated and a laminated model 120 formed on the base material using the wire 21. In the example shown in FIG. 1, the base material 110 has a rectangular shape (plate shape) and is arranged so that its surface faces vertically upward. Further, in the example shown in FIG. 1, the laminated model 120 as an example of the laminated body has a cylindrical shape, and an opening provided in itself is formed on the surface of the base material 110 so as to face vertically upward. ing.

In the present embodiment, the structure 100 including the base material 110 and the laminated model 120 may be the final product. Further, the laminated model 120 obtained by removing the base material 110 from the structure 100 may be the final product. Further, in any case, the work piece 130 (see also FIG. 11D described later) obtained by subjecting the laminated model 120 to various machining including cutting may be the final product.

(Base material)
The base material 110 serves as a base for the laminated model 120. As the base material 110, a metal material capable of forming the laminated model 120 by a so-called welding process can be used. Further, in consideration of ensuring stability during laminated modeling, it is desirable to use a plate material as shown in FIG. 1 as the laminated model 120.

(Laminated model)
The laminated model 120 has a structure in which a plurality of beads 121, each of which is formed by melting and solidifying the wire 21, are stacked toward the upper side in the vertical direction. Then, in the laminated model 120 shown in FIG. 1, the n-layer beads 121 (specifically, the first-layer beads 121 (1) to the n-layer beads 121 (n)) are stacked to form a laminated model. 120 is configured.

[Operation of metal laminated molding system]
Subsequently, the operation of the metal laminated modeling system 1 shown in FIG. 1 will be described.
In the metal laminated modeling system 1 of the present embodiment, first, the planning creation device 40 creates an output data Do including a control program and various data used in forming the laminated model 120, and also creates the output data. Do is written on the recording medium 50. Then, the laminated modeling apparatus 60 operates according to the control program (and various data) included in the output data Do read from the recording medium 50, and forms the laminated model 120 on the base material 110. Therefore, in the following, the operation of the planning apparatus 40 will be described first, and then the operation of the laminated modeling apparatus 60 will be described.

(Operation of planning device)
FIG. 6 is a flowchart showing an operation example of the plan creation device 40. Here, it is assumed that the three-dimensional CAD data D3d relating to the modeled object that is the basis of the laminated modeled object 120 to be manufactured has already been created by the CAD device 2.

When the operation of the plan creation device 40 starts, the acquisition unit 401 first acquires the three-dimensional CAD data D3d from the CAD device 2 (step 10).

Next, the conversion unit 402 converts the three-dimensional CAD data D3d received from the acquisition unit 401 into the internal data Di (step 20).

Subsequently, the cutting unit 403 creates layer shape data Ds using the internal data Di received from the conversion unit 402 (step 30).

Further, the dividing unit 404 creates the divided layer shape data Dd using the layer shape data Ds received from the cutting unit 403 (step 40: an example of the step of determining).

Next, the stretching unit 405 creates the stretched layer shape data De using the divided layer shape data Dd received from the dividing unit 404 (step 50: an example of the step of modifying).

Further, the creating unit 406 creates the control data Dc using the stretched layer shape data De created by the stretching unit 405 (step 60).

Further, the addition unit 407 uses the control program executed by the control device 30 of the laminated modeling device 60, the stretched layer shape data De received from the stretching unit 405, and the control data Dc received from the creating unit 406. The output data Do is created (step 70).

Then, the output unit 408 outputs the output data Do received from the addition unit 407 by writing it on the recording medium 50 (step 80).
As described above, the operation of the planning device 40 is completed.

(Operation of laminated modeling equipment)
FIG. 7 is a flowchart showing an operation example of the laminated modeling apparatus 60. However, FIG. 7 actually shows the operation procedure of the control device 30 constituting the laminated modeling device 60. Before the laminated modeling device 60 starts operating according to the procedure shown in FIG. 7, the base metal 110 is positioned at a predetermined position in the periphery of the robot device 10 in a fixed state. And. Further, steps 110 to 190, which will be described below, are examples of manufacturing processes.

When the laminated modeling apparatus 60 starts operation, first, the reception unit 301 accepts the input of the output data Do read from the recording medium 50 (step 110; an example of the accepting step).

Next, the overall control unit 302 applies the control program included in the output data Do received in step 110 to various data (stretched layer shape data De and control data Dc) included in the output data Do also received in step 110. Execute while referring to. Further, the overall control unit 302 sets the variable x to 1 (step 120).

Subsequently, the overall control unit 302 creates an instruction (hereinafter referred to as “layer formation instruction”) for forming the bead 121 of the xth layer (first layer) (step 130).

Further, the overall control unit 302 is instructed to search for the arc generation point (the place where the arc is first generated) of the bead 121 of the xth layer based on the layer formation instruction of the xth layer created in step 130 (hereinafter,). Then, a “search instruction”) is created and output to the robot control unit 303 and the camera control unit 305 (step 140). Then, the robot device 10 operates based on the search instruction, and the camera 25 takes a picture of the bead 121 already formed on the base material 110 or on the base material 110. Then, the overall control unit 302 searches for the arc start point used in forming the bead 121 of the x-th layer based on the imaging result (infrared image) captured by the camera 25.

Next, the overall control unit 302 determines whether or not the arc generation point used in forming the bead 121 of the x-th layer can be specified (step 150). If a negative determination (No) is made in step 150, the process returns to step 140 to continue the process.

Here, slag due to flux or the like contained in the wire 21 may be attached to the bead 121 formed on the base material 110. In general, slag is often an insulator made of a metal oxide or the like, and it is difficult to generate an arc at a portion to which slag is attached. Then, for example, in the bead 121 immediately after formation, the surface temperature of the portion to which the slag is not attached is higher than that of the portion to which the slag is attached because the film made of metal oxide or the like is not present. There are many.

Therefore, in the present embodiment, the overall control unit 302 observes the temperature of the surface of the bead 121 based on the infrared image taken by the camera 25, and the temperature is higher than the predetermined temperature. The determined portion is set as the arc start point used in the formation of the bead 121 of the x-th layer.

On the other hand, when a positive judgment (Yes) is made in step 150, in other words, when the arc generation point used for forming the bead 121 of the x-th layer can be specified, the overall control unit 302 is created in step 130. The layer formation instruction of the x-th layer is corrected in consideration of the specified arc generation point (step 160: an example of the process of correction).

Then, the overall control unit 302 outputs the layer formation instruction of the xth layer modified in step 160 (hereinafter referred to as “corrected layer formation instruction”) to both the robot control unit 303 and the welding control unit 304. (Step 170). Then, the robot device 10 and the welding torch 20 operate in cooperation with each other based on the search instruction, and the bead 121 of the x-th layer is placed on the base material 110 or the bead 121 already formed on the base material 110. (An example of a step of forming the bead of the xth layer and a step of forming the bead of the x + 1th layer).

Then, the overall control unit 302 determines whether or not the variable x is equal to the total number of layers n of the laminated model 120 (step 180).

When a negative determination (No) is made in step 180, the overall control unit 302 updates the variable x to x + 1 (step 190), returns to step 130, and continues processing related to the next layer.

On the other hand, when a positive determination (Yes) is made in step 180, the overall control unit 302 ends a series of processes.
From the above, it is possible to obtain the structure 100 in which the laminated model 120 formed by laminating a plurality of beads 121 on the base material 110 is formed. As a result, the operation of the laminated modeling apparatus 60 is completed.

In the above description, when a negative determination (No) is made in step 150, the identification of the arc generation point is continued, but the present invention is not limited to this. For example, the robot device 10 is operated to confront the tip of the wire 21 held by the welding torch 20 with the formed bead 121, and in this state, the wire 21 is advanced and retreated by using the welding torch 20 to advance and retreat the bead. The slag attached to 121 may be pierced and destroyed, and this portion may be set as the arc generation point. That is, the arc generation point may be created instead of specifying the arc generation point. Further, instead of using the welding torch 20 to move the wire 21 forward and backward, the welding torch 20 holding the wire 21 is vibrated to pierce and destroy the slag adhering to the bead 121, and this portion is the arc generation point. It may be a process to be set to. Such a process corresponds to an example of the removing step.

[Concrete example]
Then, the manufacture of the structure 100 using the above-mentioned metal laminated molding system 1 will be described with reference to specific examples. Here, as shown in FIG. 1, a case where the structure 100 is manufactured by forming the laminated model 120 having a cylindrical shape on the base material 110 having a rectangular shape is taken as an example.

(Various data)
First, various data used in the production of the laminated model 120 will be described.
8 (a) to 8 (d) and FIGS. 9 (a) to 9 (c) are diagrams for explaining the concept of various data used in the planning apparatus 40 in manufacturing the laminated model 120. The various data described here are actually expressed in binary format, ASCII format, etc., but here, in order to aid understanding, a schematic notation is used. Then, in FIGS. 8 (a) to 8 (d), the entire data is represented as a three-dimensional shape (perspective view), and in FIGS. 9 (a) to 9 (c), one layer of each data is shown. Data is shown as a two-dimensional shape (top view).

[3D shape data]
FIG. 8A shows an example of the three-dimensional CAD data D3d.
As described above, the three-dimensional CAD data D3d shown in FIG. 8A is created by the CAD device 2 and acquired by the acquisition unit 401 of the plan creation device 40. Although not described here, the internal data Di created by the conversion unit 402 of the plan creation device 40 is also different in the expression format, and the shape itself to be expressed is the same as the three-dimensional CAD data D3d. is there.

[Layer shape data]
FIG. 8B shows an example of layer shape data Ds. Further, FIG. 9A shows an example of the layer shape data Ds (1) of the first layer constituting the layer shape data Ds shown in FIG. 8B.

As described above, the layer shape data Ds shown in FIG. 8B is created by the cutting portion 403 of the planning apparatus 40. In this example, the layer shape data Ds has an n-layer structure including the layer shape data Ds (1) to the nth layer of the first layer and the layer shape data Ds (n) of the nth layer.

Further, the layer shape data Ds (1) of the first layer shown in FIG. 9A is a circle corresponding to the fact that the original three-dimensional CAD data D3d (internal data Di) has a cylindrical shape. It is designed to have a ring shape.

Although detailed description is not given here, each of the layer shape data Ds (2) of the second layer to the layer shape data Ds (n) of the nth layer also exhibits 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 nth layer each exhibit the same shape.

[Divided layer shape data]
FIG. 8C shows an example of the divided layer shape data Dd. Further, FIG. 9B shows an example of the divided layer shape data Dd (1) of the first layer constituting the divided layer shape data Dd shown in FIG. 8C.

As described above, the divided layer shape data Dd shown in FIG. 8C is created by the division unit 404 of the plan creation device 40. The divided layer shape data Dd (1) of the first layer shown in FIG. 9B corresponds to the fact that the original layer shape data Ds (1) of the first layer has an annular shape. Therefore, it is designed to have an annular shape.

Further, in the divided layer shape data Dd (1) of the first layer, a division point Pd is set at one place on the circumference of the original layer shape data Ds (1) of the first layer. Then, in the divided layer shape data Dd (1) of the first layer in which the division point Pd is set, the side adjacent to one end of the division point Pd is set as the temporary start point Pts, and the other end of the division point Pd is set. The adjacent side is set to the temporary end point Pte. As a result, the divided layer shape data Dd (1) of the first layer can be expressed in one pass (so-called one-stroke writing) from the temporary start point Pts to the temporary end point Pte without passing through the division point Pd. It has become.

Although detailed description is not given here, the division point Pd and the provisional start point are also obtained for each of the divided layer shape data Dd (2) to the nth layer divided layer shape data Dd (n). Three of Pts and temporary end point Pte are set. Then, in this example, in the divided layer shape data Dd (1) to the nth layer divided layer shape data Dd (n) having a common shape, the division point Pd, the temporary start point Pts, and the temporary end point Each of the Pte is arranged so as to overlap when viewed from above vertically.

[Stretched layer shape data]
FIG. 8D shows an example of stretched layer shape data De. Further, FIG. 9 (c) shows an example of the stretched layer shape data De (1) of the first layer constituting the stretched layer shape data De shown in FIG. 8 (d).

As described above, the stretched layer shape data De shown in FIG. 8D is created by the stretched portion 405 of the planning device 40. Then, in the stretched layer shape data De (1) of the first layer shown in FIG. 9 (c), the divided layer shape data Dd (1) of the first layer, which is the original, has an annular shape. Correspondingly, although it is basically an annular shape, it has a shape in which a part of its outer peripheral surface is provided with a protrusion protruding outward. Then, in the stretched layer shape data De (1) of the first layer, such a protrusion is a setting site of the division point Pd, more specifically, a temporary start point Pts and a division point which are one ends of the division point Pd. It extends from both of the temporary end points Pte, which is the other end of the above. More specifically, this protrusion is a portion of the stretched layer shape data De (1) of the first layer that is stretched from the temporary start point Pts to the start point Ps set on the outside thereof. It is configured by arranging adjacent portions extending from the temporary end point Pte to the end point Pe set on the outside thereof. As a result, the stretched layer shape data De (1) of the first layer in which the start point Ps and the end point Pe are set sets the division point Pd from the start point Ps to the end point Pe via the temporary start point Pts and the temporary end point Pte. It is in a state where it can be expressed in one pass (so-called one-stroke writing) without passing. Here, the start point Ps is an example of a new start point, and the end point Pe is an example of a new end point.

Although detailed description is not given here, the start point Ps and the end point Pe are also described for each of the stretched layer shape data De (2) to the nth layer stretched layer shape data De (n). Two are set. In this example, in the stretched layer shape data De (1) to the nth layer stretched layer shape data De (n) having a common shape, the start point Ps and the end point Pe are also vertical. They are arranged so that they overlap when viewed from above.

[Each route in stretched layer shape data]
FIG. 10 is a diagram for explaining various routes in the stretched layer shape data De. However, FIG. 10 illustrates the first stretched layer shape data De (1) that constitutes the stretched layer shape data De, as in FIG. 9 (c) described above.

In the present embodiment, the path from the start point Ps to the end point Pe via the provisional start point Pts and the provisional end point Pte without straddling the division point Pd is referred to as "formation path Rf". Further, among the formation paths Rf, the path from the temporary start point Pts to the temporary end point Pte without straddling the division point Pd (in this example, the path exhibiting a substantially circular shape) is referred to as “product path Rp”. Further, among the formation paths Rf, the path from the start point Ps to the temporary start point Pts is referred to as "start point side extension path Rs". Furthermore, among the formation paths Rf, the path from the temporary end point Pte to the end point Pe is referred to as "end point side extension path Re". Here, in the present embodiment, the start point side extension path Rs and the end point side extension path Re are examples of the extension region.

Therefore, the start point Ps, the provisional start point Pts, the provisional end point Pte, and the end point Pe are connected by one path by the formation path Rf including the start point side extension path Rs, the product path Rp, and the end point side extension path Re. ..

Here, the product route Rp is a route that already exists in the divided layer shape data Dd (see FIGS. 8 (c) and 9 (b)). On the other hand, the start point side stretching path Rs and the ending point side stretching path Re do not exist in the divided layer shape data Dd, and the stretched layer shape data De (see FIGS. 8 (d) and 9 (c)). This is the first route to appear.

(Structure)
Subsequently, the production of the structure 100 including the laminated model 120 using the various data shown in FIGS. 8 to 10 will be described.
11 (a) to 11 (d) are views showing an example of a manufacturing process of the structure 100.
Further, FIGS. 12 (a) to 12 (d) are views showing an example of a laminating procedure of the first layer and the second layer beads 121 in the manufacturing process of the structure 100 shown in FIG.
Here, a case where the total number of layers of the beads 121 constituting the laminated model 120 is 5 (n = 5) will be described as an example.

[Formation of the first layer bead]
FIG. 11A is a perspective view showing a state after the first layer bead 121 (1) is formed on the base material 110 based on the stretched layer shape data De (1) of the first layer. .. Further, FIG. 12A is a top view showing a state before forming the first layer bead 121 (1). Further, FIG. 12B is a top view showing a state after forming the first layer bead 121 (1).

Here, as shown in FIG. 12A, the stretched layer shape data De (1) of the first layer, which is the source of the bead 121 (1) of the first layer, includes the start point Ps (1) of the first layer. 1) The temporary start point Pts (1) of the first layer, the temporary end point Pte (1) of the first layer, and the end point Pe (1) of the first layer are set.

Then, by driving the robot device 10 using the stretched layer shape data De (1) of the first layer, the wire 21 held by the welding torch 20 is placed on the base metal 110 as the starting point Ps of the first layer. From (1), the first layer extension path Rs (1), the first layer temporary start point Pts (1), the first layer product path Rp (1), and the first layer temporary end point Pte (1). The extension path Re (1) on the end point side of the first layer and the end point Pe (1) of the first layer are moved in this order. As a result, as shown in FIG. 11A and the like, the first layer bead 121 (1) is formed on the base material 110.

[Formation of the second layer bead]
FIG. 11B shows a state after the second layer bead 121 (2) is formed on the first layer bead 121 (1) based on the stretched layer shape data De (2) of the second layer. It is a perspective view which shows. Further, FIG. 12 (c) is a diagram showing a state after the first layer bead 121 (1) is formed and before the second layer bead 121 (2) is formed. Further, FIG. 12 (d) is a top view showing a state after forming the second layer bead 121 (2).

Here, the stretched layer shape data De (2) of the second layer, which is the source of the bead 121 (2) of the second layer, also has the start point Ps (2) of the second layer as shown in FIG. 12 (c). 2) The temporary start point Pts (2) of the second layer, the temporary end point Pte (2) of the second layer, and the end point Pe (2) of the second layer are set. In this example, since the stretched layer shape data De (1) of the first layer and the stretched layer shape data De (2) of the second layer have the same shape, the two layers The start point Ps (2) of the eyes is the start point Ps (1) of the first layer, the temporary start point Pts (2) of the second layer is the temporary start point Pts (1) of the first layer, and the temporary end point Pte of the second layer (2). 2) is a position where the temporary end point Pte (1) of the first layer and the end point Pe (2) of the second layer overlap with the end point Pe (1) of the first layer.

Then, in the present embodiment, before forming the second layer bead 121 (2), the arc generation point is searched for on the already formed first layer bead 121 (1). More specifically, the search for the arc generation point is generated from the portion of the bead 121 (1) of the first layer corresponding to the extension path Rs (1) on the start point side of the first layer with welding. It is performed by detecting the part where the slag is not attached (the part where the slag is not attached) (an example of the detection step).

Then, in the present embodiment, the stretched layer shape data De (2) of the second layer shown in FIG. 12 (c) is corrected by adding the detected non-adhered portion. More specifically, in the present embodiment, the stretched layer shape data De (2) of the second layer shown in FIG. 12 (c) is corrected to correct the detected non-adhered portion to the starting point Ps. .. As a result, the stretched layer shape data De (2) of the second layer is modified from the state shown in FIG. 12 (c) to, for example, the state shown in FIG. 12 (d). In the example shown in FIG. 12 (d), the start point Ps is moved to the provisional start point Pts side as compared with the example shown in FIG. 12 (c).

Then, by driving the robot device 10 using the modified second layer stretched layer shape data De (2), the wire 21 held by the welding torch 20 is transferred to the second layer on the base material 110. From the start point Ps (2) of the second layer, the extension path Rs (2) on the start point side of the second layer, the temporary start point Pts (2) of the second layer, the product path Rp (2) of the second layer, and the temporary end point Pte of the second layer. (2) The extension path Re (2) on the end point side of the second layer and the end point Pe (2) of the second layer are moved in this order. As a result, as shown in FIG. 11B and the like, the second layer bead 121 (2) is formed on the first layer bead 121 (1). At this time, since the start point Ps (2) of the second layer is corrected to the non-adhered portion where the slag is not attached, in the formation of the bead 121 (2) of the second layer, the arc generation failure and the like Hard to occur.

After that, the bead 121 (3) of the third layer, the bead 121 (4) of the fourth layer, and the bead 121 (5) of the fifth layer are laminated while correcting the starting point Ps in the same procedure.

[Formation of beads in the nth layer (n = 5)]
FIG. 11C shows that the fifth layer bead 121 (5), which is the final layer, is formed on the fourth layer bead 121 (4) based on the stretched layer shape data De (5) of the fifth layer. It is a figure which shows the state after forming, that is, the state after forming a laminated model 120 on a base material 110.

In the case of the present embodiment, the shape of the obtained laminated model 120 is such that a protrusion extending in the vertical direction is formed on the outer peripheral surface side of the original cylindrical model. Further, since the bead 121 is formed by using a welding process, unevenness due to the bead 121 is present on the outer peripheral surface and the inner peripheral surface thereof.

〔processing〕
FIG. 11D shows a work piece 130 obtained by machining the laminated model 120 shown in FIG. 11C.
Here, the workpiece 130 shown in FIG. 11D has a substantially flat outer peripheral surface 131 as a result of being subjected to a cutting process for removing the protrusions on the laminated model 120 shown in FIG. 11C. It has an inner peripheral surface 132 in which unevenness remains as it is without being particularly machined. As a result, the shape of the workpiece 130 can be made closer to the shape of the original modeled object (three-dimensional CAD data D3d). If the inner peripheral surface 132 is also subjected to the same cutting process as the outer peripheral surface 131, the shape of the workpiece 130 can be made closer to the shape of the original modeled object.

[Other]
In the above-described embodiment, when the laminated model 120 is manufactured based on the three-dimensional CAD data D3d of the model, protrusions based on the start point side extension path Rs and the end point side extension path Re are formed on the laminated model 120. I tried to do it, but it is not limited to this.

FIG. 13 is a diagram showing another example of the laminated model 120 manufactured by the manufacturing method of the present embodiment.
In this example, after the plan creation device 40 creates the divided layer shape data Dd shown in FIG. 8C, the output including the divided layer shape data Dd is output without creating the stretched layer shape data De. Create data Do and output it. Then, in the laminated modeling apparatus 60, every time the bead 121 of one layer is formed, the arc generation point is searched, and the start point Ps (described as a temporary start point Pts in the example shown in FIG. 10 and the like) and the end point Pe (FIG. 10 and the like) are searched. In the example shown in, the provisional end point Pte) is modified. This is equivalent to modifying (changing) the division point Pd for each layer.
Even in this case, when starting the formation of the bead 121 of each layer, it is possible to suppress the poor formation of the bead 121 due to the poor generation of the arc.

In the present embodiment, in the formation of the laminated model 120 having a cylindrical shape, the protrusions are extended outward, but the present invention is not limited to this, and the protrusions are directed inward. It may be stretched.

Further, in the present embodiment, the camera 25 is attached to the robot device 10, but the present invention is not limited to this, and the camera is located in a place different from the robot device 10 as long as the base material 110 or the like can be photographed. You may install 25.

Further, in the present embodiment, the search for the arc generation point is performed based on the shooting result by the camera 25, but the present invention is not limited to this, and for example, the measurement result of the electric resistance (contact resistance) of the bead 121 can be used. Based on this, the search for the arc generation point may be performed.

Furthermore, in the present embodiment, the plan creation device 40 converts the three-dimensional CAD data D3d into the internal data Di and then performs various processes, but the present invention is not limited to this, and for example, the three-dimensional CAD data. The layer shape data Ds may be created directly from D3d.

1 ... Metal laminated modeling system, 2 ... CAD device, 10 ... Robot device, 20 ... Welding torch, 21 ... Wire, 25 ... Camera, 30 ... Control device, 40 ... Planning device, 50 ... Recording medium, 60 ... Laminated modeling Device, 100 ... structure, 110 ... base material, 120 ... laminated model, 121 ... bead, 130 ... work piece, 131 ... outer peripheral surface, 132 ... inner peripheral surface, 301 ... reception unit, 302 ... overall control unit, 303 ... Robot control unit, 304 ... Welding control unit, 401 ... Acquisition unit, 402 ... Conversion unit, 403 ... Cutting unit, 404 ... Dividing unit, 405 ... Stretching unit, 406 ... Creating unit, 407 ... Addition unit, 408 ... Output unit , D3d ... 3D CAD data, Di ... Internal data, Ds ... Layer shape data, Dd ... Divided layer shape data, De ... Stretched layer shape data, Dc ... Control data, Pd ... Division point, Pts ... Temporary start point Ps ... start point, Pte ... temporary end point, Pe ... end point, Rf ... stacking path, Rp ... product path, Rs ... start point side extension path, Re ... end point side extension path

Claims (8)

A method for manufacturing a modeled object, which comprises a laminated body in which a plurality of beads formed by melting and solidifying a filler metal by using an arc are produced based on three-dimensional shape data.
A step of determining the division point of each layer from the slice data obtained by dividing the three-dimensional shape data into a plurality of layers, and
A step of setting a start point formed by extending one end side of the division point and an end point formed by extending the other end side of the division point, and modifying the slice data by adding the start point and the end point. ,
It has a step of manufacturing the modeled object by forming a bead from the start point to the end point based on the modified slice data.
In the manufacturing step, among the beads already formed, the non-adhered portion to which the slag is not adhered is identified from the stretched region stretched by adding the start point and the end point, and the said A method for manufacturing a modeled object, in which a non-adhered portion is corrected to the starting point to form the next bead. The method for manufacturing a modeled object according to claim 1, wherein the non-adhered portion is specified by extracting a region to which slag is attached from an image obtained by imaging the surface of a bead that has already been formed. The production of the model according to claim 1, further comprising a step of removing the slag adhering to the bead by abutting the filler material or a welding torch holding the filler metal against the already formed bead. Method. A method for manufacturing a modeled object, which comprises a laminated body in which a plurality of beads formed by melting and solidifying a filler metal by using an arc are produced based on three-dimensional shape data.
A process of receiving output data in which division points are set in each layer of slice data obtained by dividing the three-dimensional shape data into a plurality of layers, and
Based on the data of the xth layer (x is an integer of 2 or more) in the received output data, the start point is one end side of the division point, the other end side of the division point is the end point, and the end point is from the start point to the end point. The process of forming the x-th layer bead toward
From the formed bead of the xth layer, the process of detecting the non-adhered part where the slag is not attached, and
A step of modifying the data of the x + 1 layer of the output data so that the non-attached portion in the bead of the x layer becomes the starting point.
A method for manufacturing a modeled object, which comprises a step of forming a bead of the x + 1 layer on the bead of the x + 1 layer based on the modified data of the x + 1 layer. In the accepting step, the output data to which a new start point obtained by extending the start point and a new end point obtained by extending the end point are added is received.
In the detection step, the non-adhered portion is detected from the stretched region stretched by adding the new start point and the new end point in the formed bead of the xth layer. The method for manufacturing a modeled object according to claim 4. The method for producing a modeled object according to claim 4 or 5, wherein in the detection step, the non-adhered portion is detected using an image obtained by capturing an image of the formed bead of the xth layer. A receiving means for receiving output data in which division points are set for each layer of slice data obtained by dividing three-dimensional shape data representing the shape of a three-dimensional model into a plurality of layers.
Based on the data of the xth layer (x is an integer of 2 or more) in the received output data, the start point is one end side of the division point, the other end side of the division point is the end point, and the end point is from the start point to the end point. A first output means that outputs an instruction for forming an x-th layer bead toward
A correction means for modifying the data of the x + 1 layer of the output data so that the non-adhered portion to which the slag is not attached, which is detected from the formed bead of the xth layer, becomes the starting point.
A stacking control device for a modeled object including a second output means for outputting an instruction for forming the bead of the x + 1 layer on the bead of the x + 1 layer based on the modified data of the x + 1 layer. On the computer
A function that accepts output data in which division points are set for each layer of slice data obtained by dividing three-dimensional shape data representing the shape of a three-dimensional model into multiple layers.
Based on the data of the xth layer (x is an integer of 2 or more) in the received output data, the start point is one end side of the division point, the other end side of the division point is the end point, and the end point is from the start point to the end point. The function to output the instruction to form the bead of the xth layer toward
A function of modifying the data of the x + 1 layer of the output data so that the non-attached portion to which the slag is not attached, which is detected from the formed bead of the xth layer, becomes the starting point.
A program for realizing a function of outputting an instruction for forming a bead of the x + 1 layer on the bead of the x + 1 layer based on the modified data of the x + 1 layer.