JP2022032283A - Additional manufacturing device and additional manufacturing method - Google Patents

Abstract

To provide an additional manufacturing device which can manufacture a modeled object having a high form accuracy.SOLUTION: An additional manufacturing device 100 manufactures a modeled object having a shape designated by design data 26. The additional manufacturing device 100 comprises: a wire feeder 7 as a feeding part for feeding a wire 5, which is a filler material, to a work-piece; a laser oscillator 1 as an irradiation part for radiating beam for melting the fed filler material; an intensity distribution adjusting part 19 which adjusts intensity distribution of beam in the work-piece; and an intensity distribution calculating part which determines intensity distribution by calculation on the basis of the design data 26.SELECTED DRAWING: Figure 1

Description

The present disclosure relates to an addition manufacturing apparatus and an addition manufacturing method for manufacturing a three-dimensional model.

As one of the techniques for manufacturing a three-dimensional model, the technique of additive manufacturing (AM) is known. According to the Directed Energy Deposition (DED) method, which is one of several methods in the additive manufacturing technology, the additive manufacturing device is a wire that is a filler material to the processing point, which is the irradiation position of the beam. Alternatively, a bead is formed by moving the processing point while supplying the powder. The bead is a solidified product obtained by solidifying the molten filler material. The movement path of the machining point is generated based on the design data. The additional manufacturing apparatus manufactures a modeled object by sequentially stacking beads.

Patent Document 1 discloses an additional manufacturing apparatus including an optical system that converts an intensity distribution of a beam in a cross section of the beam and a spatial light modulation unit that spatially modulates the state of the beam. The additional manufacturing apparatus of Patent Document 1 can measure the state of the surface of the work piece on which the bead is formed and adjust the intensity distribution of the beam according to the state of the work piece.

Japanese Unexamined Patent Publication No. 2018-141240

In the additional manufacturing apparatus, even if the output of the beam is appropriate, the shape of the bead to be formed may deviate from the desired shape due to an excess or deficiency of the amount of heat input when melting the filler metal. In the conventional additive manufacturing apparatus disclosed in Patent Document 1, since adjustments for reducing such shape deviation are not performed, there is a problem that the shape accuracy of the modeled object may be lowered. ..

The present disclosure has been made in view of the above, and an object of the present disclosure is to obtain an additive manufacturing apparatus capable of manufacturing a modeled object having high shape accuracy.

In order to solve the above-mentioned problems and achieve the object, the additive manufacturing apparatus according to the present disclosure manufactures a modeled object having a shape specified by the design data. The additional manufacturing apparatus according to the present disclosure adjusts the intensity distribution of the beam in the workpiece, the supply unit that supplies the filler material to the workpiece, the irradiation unit that irradiates the beam that melts the supplied filler metal, and the beam. It is provided with an intensity distribution adjusting unit and an intensity distribution calculation unit for obtaining an intensity distribution by an operation based on design data.

The addition manufacturing apparatus according to the present disclosure has an effect that it is possible to manufacture a modeled object having high shape accuracy.

The figure which shows the structure of the addition manufacturing apparatus which concerns on Embodiment 1. The block diagram which shows the structure of the arithmetic unit which the addition manufacturing apparatus which concerns on Embodiment 1 has. The first flowchart which shows the operation procedure of the addition manufacturing apparatus which concerns on Embodiment 1. The second flowchart which shows the operation procedure of the addition manufacturing apparatus which concerns on Embodiment 1. The figure which shows the structural example of the strength distribution adjustment part which the addition manufacturing apparatus which concerns on Embodiment 1 has. The first figure for demonstrating the example of the intensity distribution adjustment by the intensity distribution adjustment part shown in FIG. The second figure for demonstrating the example of the intensity distribution adjustment by the intensity distribution adjustment part shown in FIG. The figure for demonstrating another example of the intensity distribution adjustment by the intensity distribution adjustment part shown in FIG. The figure for demonstrating the operation of the addition manufacturing apparatus which concerns on Embodiment 2. The first figure for demonstrating the adjustment of the intensity distribution in Embodiment 2. The second figure for demonstrating the adjustment of the intensity distribution in Embodiment 2. The figure for demonstrating the modification of the intensity distribution adjustment in Embodiment 2. The figure for demonstrating the operation of the addition manufacturing apparatus which concerns on Embodiment 3. The figure for demonstrating the adjustment of the intensity distribution in Embodiment 3. The figure for demonstrating the operation of the addition manufacturing apparatus which concerns on Embodiment 4. The figure for demonstrating the operation of the addition manufacturing apparatus which concerns on Embodiment 5. The first figure for demonstrating the operation of the addition manufacturing apparatus which concerns on Embodiment 6. The second figure for demonstrating the operation of the addition manufacturing apparatus which concerns on Embodiment 6. The first figure for demonstrating the operation of the addition manufacturing apparatus which concerns on Embodiment 7. The second figure for demonstrating the operation of the addition manufacturing apparatus which concerns on Embodiment 7. The figure for demonstrating the 1st bead formed in Embodiment 8. The figure for demonstrating the 2nd bead formed in Embodiment 8. FIG. 1 for explaining a modeled object manufactured by using the first bead in the addition manufacturing apparatus according to the eighth embodiment. FIG. 2 for explaining a modeled object manufactured by using the first bead in the addition manufacturing apparatus according to the eighth embodiment. The figure for demonstrating the shaped object manufactured by using the 2nd bead in the addition manufacturing apparatus which concerns on Embodiment 8. The first figure for demonstrating the selection example of the beam shape by Embodiment 8. The second figure for demonstrating the selection example of the beam shape by Embodiment 8. FIG. 3 for explaining an example of selecting a beam shape according to the eighth embodiment. The block diagram which shows the structure of the arithmetic unit which the addition manufacturing apparatus which concerns on Embodiment 9 has. The block diagram which shows the functional structure of the learning apparatus which the addition manufacturing apparatus which concerns on Embodiment 9 has. A flowchart showing a processing procedure of the learning device according to the ninth embodiment. The block diagram which shows the functional structure of the inference apparatus which the addition manufacturing apparatus which concerns on Embodiment 9 has. A flowchart showing a processing procedure of the inference device according to the ninth embodiment. The figure which shows the hardware configuration example of the arithmetic unit which the addition manufacturing apparatus which concerns on Embodiment 1 to 9 has.

Hereinafter, the addition manufacturing apparatus and the addition manufacturing method according to the embodiment will be described in detail with reference to the drawings.

Embodiment 1.
FIG. 1 is a diagram showing a configuration of an addition manufacturing apparatus according to the first embodiment. The addition manufacturing apparatus 100 according to the first embodiment is a machine tool that manufactures a modeled object by adding a molten filler material to a workpiece. The addition manufacturing apparatus 100 melts the filler metal by irradiating the beam. In the first embodiment, the beam is a laser beam 10 and the filler material is a metal wire 5. The wire 5 may be other than metal. The filler material is not limited to the wire 5, and may be a metal or resin powder. The additional manufacturing apparatus 100 manufactures a modeled object having a shape specified by the design data 26.

The addition manufacturing apparatus 100 forms the bead 8 by moving the processing point 9 while supplying the wire 5 to the processing point 9 which is the irradiation position of the laser beam 10. The addition manufacturing apparatus 100 manufactures a three-dimensional model by stacking beads 8 on a base material 11. The base material 11 shown in FIG. 1 is a plate material. The base material 11 may be a material other than a plate material. The workpiece is an object to which the molten filler material is added, and is a base material 11 or a bead 8 on the base material 11. In the first embodiment, the X-axis, the Y-axis, and the Z-axis are three axes perpendicular to each other. The X-axis and the Y-axis are horizontal axes. The Z axis is a vertical axis. In each of the X-axis direction, the Y-axis direction, and the Z-axis direction, the direction indicated by the arrow may be referred to as a positive direction, and the direction opposite to the arrow may be referred to as a negative direction.

The laser oscillator 1 which is a beam source oscillates the laser beam 10. The laser beam 10 output by the laser oscillator 1 propagates to the processing head 3 through the fiber cable 2 which is an optical transmission path. The laser oscillator 1, the fiber cable 2, and the processing head 3 constitute an irradiation unit that irradiates the workpiece with a laser beam 10 that melts the supplied filler metal. The laser output controller 18 controls the laser oscillator 1.

Inside the processing head 3, a collimating optical system for parallelizing the laser beam 10 and an intensity distribution adjusting unit 19 are provided. The intensity distribution adjusting unit 19 adjusts the intensity distribution of the laser beam 10 in the workpiece. The intensity distribution controller 17 controls the intensity distribution adjusting unit 19. The illustration of the collimating optical system is omitted.

The processing head 3 has a beam nozzle 4 that emits a laser beam 10 toward a work piece. The laser beam 10 passes through the condenser lens and is emitted from the beam nozzle 4. The condenser lens aggregates the laser beam 10 in the workpiece. The illustration of the condenser lens is omitted. The collimating optical system and the condenser lens are designed so that the spot size of the laser beam 10 at the processing point 9 becomes a desired size.

The intensity distribution adjusting unit 19 adjusts the intensity distribution according to the control signal from the intensity distribution controller 17. When the intensity distribution adjusting unit 19 does not adjust the intensity distribution, the intensity distribution of the laser beam 10 in the workpiece is the intensity distribution determined by the optical element group other than the intensity distribution adjusting unit 19. By adjusting the intensity distribution, the intensity distribution adjusting unit 19 converts the intensity distribution of the laser beam 10 in the workpiece into an intensity distribution different from the intensity distribution defined by the optical element group other than the intensity distribution adjusting unit 19. Let me.

The beam nozzle 4 injects a shield gas toward the workpiece. As the shield gas, argon gas, which is an inert gas, is used. The addition manufacturing apparatus 100 suppresses the oxidation of the bead 8 and cools the formed bead 8 by injecting the shield gas. The shield gas is supplied to the beam nozzle 4. The gas flow rate regulator 21 adjusts the flow rate of the shield gas supplied to the beam nozzle 4. The source of the shield gas is a gas cylinder. Illustration of the gas cylinder is omitted.

A wire spool 6 which is a supply source of the wire 5 is attached to the additional manufacturing apparatus 100. The wire 5 is wound around the wire spool 6. The wire feeder 7 is attached to the processing head 3. The wire feeder 7 is a supply unit that supplies a filler material to the workpiece. The wire feeder 7 feeds the wire 5 from the wire spool 6 toward the workpiece. Further, the wire feeder 7 pulls the sent out wire 5 back toward the wire spool 6. Since the beam nozzle 4 and the wire feeder 7 are provided on the processing head 3, the relative positions of the beam nozzle 4 and the wire feeder 7 are fixed.

The base material 11 is fixed to the rotary stage 12. The rotary stage 12 rotates about the Z axis. The rotary stage 13 changes the inclination of the rotary stage 12 by rotation around the Y axis. The XYZ stage 14 moves the machining head 3 in each of the X-axis direction, the Y-axis direction, and the Z-axis direction. The addition manufacturing apparatus 100 changes the posture of the base material 11 by the operation of the rotary stages 12 and 13. The addition manufacturing apparatus 100 moves the irradiation position of the laser beam 10 on the workpiece by changing the posture of the base material 11 and moving the machining head 3. The addition manufacturing apparatus 100 feeds the wire 5 to the molten pool formed at the processing point 9 and melts the wire 5 to form the bead 8.

The drive controller 22 drives the head drive unit 23 that moves the machining head 3 by driving the XYZ stage 14, the wire feed drive unit 24 that drives the wire feeder 7, and the rotary stages 12 and 13. It has a stage drive unit 25.

The processing head 3 is provided with a sensor unit 20 which is a measuring unit. The sensor unit 20 measures the state of the workpiece or the state of the formed bead 8. The sensor unit 20 measures the shape of the workpiece, the temperature of the workpiece, the shape of the molten pool, and the like. The sensor unit 20 generates the measurement data 30.

The additional manufacturing apparatus 100 includes an arithmetic unit 15 that performs an operation for additional manufacturing, and a numerical control (NC) apparatus 16 that controls the additional manufacturing apparatus 100. The NC device 16 controls the additional manufacturing device 100 according to the machining program 27 and the machining condition information 28 received from the arithmetic unit 15.

The design data 26 is input to the arithmetic unit 15. The design data 26 includes three-dimensional shape information for designating the shape of the modeled object and data representing various conditions at the time of processing. The three-dimensional shape information includes computer-aided design (CAD) data, STL (Standard Triangulated Language) data, and the like. The conditions include constraint conditions at the time of machining, priority conditions indicating items to be prioritized at the time of machining, weighting given to these conditions, and the like. The constraint condition is, for example, an upper limit value of the temperature during processing. By setting constraints, it is possible to keep the quality of the product within a certain range.

The design data 26 includes filler material information, laser output, intensity distribution of the laser beam 10, and the like. The filler information for the wire 5 includes information about the diameter of the wire 5 and the material of the wire 5. The design data 26 may include data of various variables that can be measured by the sensor unit 20. The various variables include variables indicating the physical properties of the filler metal such as the melting point of the wire 5 or the reflectance of the laser beam 10 at the wire 5, the temperature of the workpiece, the size of the molten pool, and the like.

The arithmetic unit 15 performs an operation for optimizing the processing program 27, the processing conditions, and the intensity distribution of the laser beam 10 based on the design data 26. The arithmetic unit 15 generates a machining program 27, machining condition information 28 representing machining conditions, and an adjustment command 29 which is a command for adjusting the intensity distribution of the laser beam 10 by calculation. The arithmetic unit 15 sends the machining program 27 and the machining condition information 28 to the NC device 16. The arithmetic unit 15 sends an adjustment command 29 to the intensity distribution controller 17.

The sensor unit 20 sends the measurement data 30 representing the measurement result to the arithmetic unit 15. The arithmetic unit 15 adjusts the machining conditions and changes the strength distribution based on the measurement data 30. When the machining condition is adjusted, the arithmetic unit 15 sends the machining condition information 28 indicating the adjusted machining condition to the NC device 16. When the intensity distribution is changed, the arithmetic unit 15 sends an adjustment command 29 for making adjustments with the changed intensity distribution to the intensity distribution controller 17.

A movement route is specified in the machining program 27. The movement path is a path for moving the processing point 9 in the workpiece. The NC apparatus 16 analyzes the movement path based on the contents described in the machining program 27.

The NC device 16 generates various commands according to the movement path and the machining conditions. The NC device 16 generates a position command which is a group of interpolation points for each unit time on the movement path. The NC device 16 controls the XYZ stage 14 by sending a position command to the head drive unit 23. The NC device 16 generates an axis command according to the description of the machining program 27. The NC device 16 controls the rotary stages 12 and 13 by sending an axis command to the stage drive unit 25.

The NC device 16 generates a laser output command 31 according to the machining program 27 and the machining conditions. The NC device 16 controls the laser oscillator 1 by sending a laser output command 31 to the laser output controller 18.

The NC device 16 generates a feeding command according to the machining program 27 and the machining conditions. The NC device 16 controls the wire feeder 7 by sending a feed command to the wire feed drive unit 24. The NC device 16 generates a gas supply command according to the machining program 27. The NC device 16 controls the gas flow rate regulator 21 by sending a gas supply command to the gas flow rate regulator 21.

The NC device 16 sends a synchronization signal 32 for linking the control of the intensity distribution adjusting unit 19 to the laser output command 31 to the intensity distribution controller 17. The NC device 16 generates a synchronization signal 32 according to the description of the machining program 27. The intensity distribution controller 17 adjusts the timing of sending the control signal to the intensity distribution adjusting unit 19 according to the synchronization signal 32. As a result, the intensity distribution adjusting unit 19 can adjust the intensity distribution according to the laser output of the laser oscillator 1.

The intensity distribution may be adjusted by the intensity distribution adjusting unit 19 together with the adjustment of the laser output by the laser oscillator 1, or may be performed in a state where the laser output by the laser oscillator 1 is constant. The addition manufacturing apparatus 100 can adjust the intensity distribution of the laser beam 10 without reducing the laser output. The addition manufacturing apparatus 100 can optimize the intensity distribution without lowering the processing speed by not lowering the laser output.

Next, the sensor unit 20 will be described. The sensor unit 20 includes a camera, a thermometer, a shape measuring instrument, and the like. The sensor unit 20 measures at at least one of the position of the machining point 9 at the start of machining, an arbitrary position in the movement path, and the position of the machining point 9 at the end of machining. The sensor unit 20 may be coaxial with the beam nozzle 4 or may not be coaxial with the beam nozzle 4. The sensor unit 20 may be provided at an arbitrary position of the processing head 3. The sensor unit 20 may be provided at a position other than the processing head 3.

The camera is a visible light camera, an infrared camera, a high speed measurement camera, or the like. The camera measures the shape of the workpiece, the molten state, the shape of the molten pool, the temperature, and the like. By providing the sensor unit 20 with a camera, the additional manufacturing apparatus 100 includes a molten state of the workpiece, a molten state of the wire 5, fume or spatter generated during machining, the position of the wire 5, the temperature of the workpiece, and the wire. The temperature of 5 and the temperature of the molten pool can be observed.

The thermometer detects the light emitted from the workpiece. The thermometer is a non-contact type thermometer such as a radiation thermometer or a thermo camera. The shape measuring instrument is a measuring instrument that measures the height in the Z-axis direction, the shape in the X-axis direction, and the Y-axis direction, and is a laser displacement meter and an optical coherence tomography (OCT) that performs optical coherence tomography. ) Etc. The sensor unit 20 may include a spectroscope, an acoustic measuring instrument, and the like.

The sensor unit 20 may perform various measurements using the branched light from the laser beam 10. A dichroic mirror arranged coaxially with the laser beam 10 can be used for branching the light. The dichroic mirror transmits light of a specific wavelength and reflects light of a wavelength other than the specific wavelength. The measurement position may be sequentially moved by driving a mirror with a galvano scanner or the like, or by using an optical element such as a prism.

Next, the processing by the arithmetic unit 15 will be described. FIG. 2 is a block diagram showing a configuration of an arithmetic unit included in the addition manufacturing apparatus according to the first embodiment. FIG. 2 shows the functional configuration of the arithmetic unit 15.

The arithmetic unit 15 includes an input unit 41 for inputting information, a route generation unit 42 for generating route data indicating a movement route, a program generation unit 43 for generating a machining program 27, and a machining condition adjustment for adjusting machining conditions. It has a unit 44 and an intensity distribution calculation unit 45 for obtaining the intensity distribution of the laser beam 10 by calculation based on the design data 26. The design data 26 and the measurement data 30 are input to the input unit 41.

The arithmetic unit 15 has a data storage unit 46 for storing data, an evaluation unit 47 for evaluating the set processing conditions and the set intensity distribution of the laser beam 10, and a bead shape determination for determining the shape of the bead 8. It has a unit 48 and a shape estimation unit 49 that estimates the shape of the modeled object based on the movement path.

The route generation unit 42 determines a movement route for manufacturing a modeled object by additional manufacturing based on the design data 26. The route generation unit 42 generates route data indicating the determined movement route. The program generation unit 43 generates a machining program 27, which is an NC program, based on the route data.

Before the machining is started, the initial value of the machining conditions is determined by the user who uses the addition manufacturing apparatus 100. In the addition manufacturing apparatus 100, machining conditions which are initial values are set before machining is started. The machining condition adjusting unit 44 adjusts the set machining conditions based on the design data 26 or the measurement data 30. The machining condition adjusting unit 44 generates machining condition information 28 representing the set machining conditions.

In the addition manufacturing apparatus 100, an initial value intensity distribution is set as the intensity distribution of the laser beam 10 before the processing is started. The intensity distribution, which is the initial value, is the intensity distribution when the intensity distribution adjusting unit 19 does not adjust the intensity distribution. That is, the intensity distribution, which is the initial value, is the intensity distribution determined by the optical element group other than the intensity distribution adjusting unit 19. The intensity distribution calculation unit 45 changes the set intensity distribution based on the design data 26 or the measurement data 30. The intensity distribution calculation unit 45 generates an adjustment command 29 for making adjustments with the set intensity distribution. The adjustment command 29 is intensity distribution information indicating the intensity distribution obtained by the intensity distribution calculation unit 45.

The bead shape determining unit 48 determines the bead shape which is the outer shape of the bead 8. The bead 8 is classified into a line bead and a point bead. The linear bead is a linear bead formed by feeding the wire 5 and irradiating the laser beam 10 while moving the processing point 9. A dot bead is a dot-shaped bead. The point bead is formed by feeding the wire 5 and irradiating the laser beam 10 with the processing point 9 stopped. The point bead may include a point bead formed while slightly moving the processing point 9. The bead shape determining unit 48 determines the bead shape for the line bead or the point bead.

Here, one example of the method of determining the movement route will be described. In this description, the bead 8 is a line bead. The path generation unit 42 obtains a two-dimensional shape which is the shape of the cut surface at a constant height from the base material 11 among the three-dimensional shapes represented by the three-dimensional shape information. The path generation unit 42 further divides the two-dimensional shape into a plurality of strip shapes. The route generation unit 42 determines a movement route including the center line of each strip shape and the movement between the center lines. The path generation unit 42 determines a movement path for a cut surface at a constant height in a three-dimensional shape.

The shape estimation unit 49 estimates the three-dimensional shape formed based on the design data 26, the set processing conditions, and the set strength distribution. The shape estimation unit 49 combines the determined movement path with the bead shape determined by the set machining conditions and the set strength distribution to obtain the design data 26, the set machining conditions, and the set strength distribution. Estimate the three-dimensional shape formed based on.

The evaluation unit 47 evaluates the quality of modeling according to the set processing conditions and the set strength distribution based on the difference between the shape shown in the design data 26 and the estimated three-dimensional shape. When it is determined that the modeling is defective, the machining condition adjusting unit 44 adjusts the set machining conditions. Alternatively, when it is determined that the modeling is defective, the intensity distribution calculation unit 45 changes the set intensity distribution.

Next, the operation procedure of the additional manufacturing apparatus 100 will be described. FIG. 3 is a first flowchart showing an operation procedure of the addition manufacturing apparatus according to the first embodiment. The first flowchart shows the operation procedure of the addition manufacturing apparatus 100 in the case of adjusting the machining conditions or changing the strength distribution before the machining is started.

In step S1, the addition manufacturing apparatus 100 acquires the design data 26. The additional manufacturing apparatus 100 acquires the design data 26 by inputting the design data 26 to the input unit 41.

In step S2, the addition manufacturing apparatus 100 sets machining conditions. Here, the machining conditions that are the initial values are set. The user can select any machining condition by referring to the machining condition table. The machining condition table lists the values of laser output, wire feed rate, and shaft feed rate. The user selects the machining conditions by selecting the initial values of the laser output, the supply amount of the wire 5, and the feed rate of the machining head 3 from the values listed in the machining condition table.

In step S3, the addition manufacturing apparatus 100 determines the bead shape. The bead shape determination unit 48 determines the bead shape by referring to the database. When the bead shape determination unit 48 determines the bead shape for a condition that is not in the database, the bead shape determination unit 48 performs an operation for estimating the bead shape based on the three-dimensional shape. The bead shape determining unit 48 may determine the bead shape based on the result of trial processing.

In step S4, the addition manufacturing apparatus 100 determines the movement route. The route generation unit 42 determines the movement route based on the three-dimensional shape shown in the design data 26 and the determined bead shape.

In step S5, the additional manufacturing apparatus 100 estimates a modeling shape which is a three-dimensional shape formed based on the design data 26, the set processing conditions, and the set strength distribution. The shape estimation unit 49 estimates the shaped shape by combining the bead shape with the determined movement path. The bead shape combined with the movement path is an estimation of the bead shape obtained when the bead 8 is formed according to the set processing conditions and the set strength distribution with the bead shape determined in step S3 as the target. be.

In step S6, the addition manufacturing apparatus 100 evaluates the modeling according to the set processing conditions and the set strength distribution. The evaluation unit 47 obtains the difference between the three-dimensional shape shown in the design data 26 and the estimated shaped shape. When the obtained difference is equal to or less than a preset threshold value, the evaluation unit 47 determines that the modeling is good. If it is determined that the modeling is good, the addition manufacturing apparatus 100 proceeds to step S8 described later. On the other hand, when the obtained difference exceeds a preset threshold value, the evaluation unit 47 determines that the modeling is defective.

If it is determined that the molding is defective, in step S7, the addition manufacturing apparatus 100 changes the strength distribution and adjusts the processing conditions. The intensity distribution calculation unit 45 adjusts the intensity distribution so that the difference is close to zero based on the above-mentioned difference. The machining condition adjusting unit 44 adjusts the machining conditions so that the difference is close to zero based on the above-mentioned difference. The addition manufacturing apparatus 100 may change the strength distribution and adjust the processing conditions so that the difference is close to zero. When the addition manufacturing apparatus 100 finishes step S7, the procedure returns to step S3.

In step S8, the addition manufacturing apparatus 100 outputs the machining program 27 and the machining condition information 28 from the arithmetic unit 15 to the NC apparatus 16. When the intensity distribution is changed from the initial value, the additional manufacturing apparatus 100 outputs an adjustment command 29 for making adjustments with the changed intensity distribution from the arithmetic unit 15 to the intensity distribution controller 17. As a result, the addition manufacturing apparatus 100 ends the operation according to the procedure shown in FIG. The addition manufacturing apparatus 100 starts machining according to the machining program 27, the set machining conditions, and the set strength distribution.

FIG. 4 is a second flowchart showing an operation procedure of the addition manufacturing apparatus according to the first embodiment. The second flowchart shows the operation procedure of the additional manufacturing apparatus 100 in the case of adjusting the machining conditions or changing the strength distribution between the start of machining and the end of machining.

In step S11, the addition manufacturing apparatus 100 acquires the machining program 27 and the machining condition information 28 in the NC apparatus 16. The addition manufacturing apparatus 100 starts machining by the control according to the machining program 27 and the machining condition information 28 by the NC device 16. In step S12, the addition manufacturing apparatus 100 performs modeling.

In step S13, the addition manufacturing apparatus 100 acquires the measurement data 30. The measurement data 30 obtained by the measurement by the sensor unit 20 is input to the input unit 41. The measurement data 30 input to the input unit 41 is stored in the data storage unit 46.

In step S14, the addition manufacturing apparatus 100 evaluates the modeling based on the acquired measurement data 30. For example, the evaluation unit 47 obtains the difference between the target shape of the modeled object and the measured shape, or the difference between the target temperature of the workpiece and the measured temperature of the workpiece at the time of machining. The evaluation unit 47 may obtain the difference between the measured value of the supply amount of the wire 5 and the target value of the supply amount. The evaluation unit 47 may obtain the difference between the measured value of the machining time, which is the time required for forming the bead 8, and the target value of the machining time. When the obtained difference is equal to or less than a preset threshold value, the evaluation unit 47 determines that the modeling is good. If it is determined that the modeling is good, the addition manufacturing apparatus 100 proceeds to step S16, which will be described later. On the other hand, when the obtained difference exceeds a preset threshold value, the evaluation unit 47 determines that the modeling is defective.

If it is determined that the molding is defective, in step S15, the addition manufacturing apparatus 100 changes the strength distribution and adjusts the processing conditions. The intensity distribution calculation unit 45 adjusts the intensity distribution so that the difference is close to zero based on the obtained difference. The machining condition adjusting unit 44 adjusts the machining conditions so that the difference is close to zero based on the above-mentioned difference. The addition manufacturing apparatus 100 may change the strength distribution and adjust the processing conditions so that the difference is close to zero. When the addition manufacturing apparatus 100 finishes step S15, the procedure returns to step S12.

In step S16, the addition manufacturing apparatus 100 determines whether or not to finish modeling. If the modeled object according to the processing program 27 is not completed, the addition manufacturing apparatus 100 determines that the modeling is not completed. If the modeling is not completed (steps S16, No), the addition manufacturing apparatus 100 returns the procedure to step S12. On the other hand, the addition manufacturing apparatus 100 determines that the modeling is completed when the modeled object according to the processing program 27 is completed. When the modeling is completed (step S16, Yes), the addition manufacturing apparatus 100 ends the operation according to the procedure shown in FIG.

Next, the intensity distribution adjusting unit 19 will be described. FIG. 5 is a diagram showing a configuration example of a strength distribution adjusting unit included in the addition manufacturing apparatus according to the first embodiment. The laser beam 10 parallelized in the collimating optical system is incident on the intensity distribution adjusting unit 19. According to the configuration example shown in FIG. 5, the intensity distribution adjusting unit 19 adjusts the intensity distribution by moving the irradiation position of the laser beam 10.

The intensity distribution adjusting unit 19 is controlled by the galvano scanners 33X and 33Y that deflect the laser beam 10, the galvano driving unit 35X that drives the galvano scanner 33X according to the control signal from the intensity distribution controller 17, and the intensity distribution controller 17. It has a galvano drive unit 35Y that drives the galvano scanner 33Y according to a signal.

The galvano scanner 33Y has a galvano mirror 34Y that reflects the laser beam 10 incident on the processing head 3. The galvano scanner 33Y moves the irradiation position of the laser beam 10 in the Y-axis direction by rotating the galvano mirror 34Y within a range of a specific swing angle.

The galvano scanner 33X has a galvano mirror 34X that reflects the laser beam 10 incident from the galvano scanner 33Y. The galvano scanner 33X moves the irradiation position of the laser beam 10 in the X-axis direction by rotating the galvano mirror 34X within a range of a specific swing angle.

The intensity distribution adjusting unit 19 has an fθ lens 36. The laser beam 10 reflected by the galvano scanner 33X is incident on the fθ lens 36. The fθ lens 36 converges the laser beam 10 at the position of fθ obtained by multiplying the focal length f of the fθ lens 36 by the deflection angles θ of the galvano mirrors 34X and 34Y. The fθ lens 36 may be provided in the optical path of the laser beam 10 before it is incident on the galvano scanners 33X and 33Y in the optical path of the laser beam 10. By using the fθ lens 36, distortion of the image plane can be reduced. The fθ lens 36 is suitable for highly accurate intensity distribution adjustment. The intensity distribution adjusting unit 19 may be provided with a lens other than the fθ lens 36 instead of the fθ lens 36.

FIG. 6 is a first diagram for explaining an example of intensity distribution adjustment by the intensity distribution adjusting unit shown in FIG. FIG. 7 is a second diagram for explaining an example of intensity distribution adjustment by the intensity distribution adjusting unit shown in FIG. In the example shown in FIGS. 6 and 7, the intensity distribution adjusting unit 19 adjusts the intensity distribution by moving the laser beam 10 while changing the intensity of the laser beam 10.

The intensity distribution adjusting unit 19 scans the path 37 with the laser beam 10. The intensity distribution adjusting unit 19 reciprocates the laser beam 10 in the Y-axis direction by the galvano scanner 33Y, and moves the laser beam 10 in the positive direction in the X-axis direction by the galvano scanner 33X.

The graph shown in FIG. 7 shows a change in the intensity of the laser beam 10 emitted from the intensity distribution adjusting unit 19. The vertical axis “P” in the graph represents the intensity of the laser beam 10. The horizontal axis "t" of the graph represents time. The intensity distribution adjusting unit 19 reduces the intensity of the laser beam 10 each time the galvano scanner 33X moves the laser beam 10. The addition manufacturing apparatus 100 changes the intensity of the laser beam 10 emitted from the intensity distribution adjusting unit 19 by changing the laser output of the laser oscillator 1. The addition manufacturing apparatus 100 uses the synchronization signal 32 to coordinate the change in the laser output and the scanning of the laser beam 10 with each other.

The intensity of the laser beam 10 gradually decreases each time the laser beam 10 reciprocates once in the Y-axis direction. The intensity distribution adjusting unit 19 adjusts the intensity distribution of the laser beam 10 in the range of the path 37 to the target intensity distributions Dx and Dy by scanning the path 37 with the laser beam 10. The intensity distribution Dy represents the intensity distribution in the Y-axis direction. The intensity of the laser beam 10 is constant while the irradiation position moves in the Y-axis direction. The intensity distribution Dx represents the intensity distribution in the X-axis direction. The intensity of the laser beam 10 decreases as the irradiation position moves in the positive direction in the X-axis direction.

The intensity distribution adjusting unit 19 may adjust the intensity distribution by a method other than the method of moving the laser beam 10 while changing the intensity of the laser beam 10. The intensity distribution adjusting unit 19 adjusts the intensity distribution by changing the output of the laser beam 10, rotating the beam outer shape, changing the size of the beam outer shape, changing the shape of the beam outer shape, changing the laser beam 10 to a multipoint beam, and the like. Is also good. The outer shape of the beam is the cross-sectional shape of the laser beam 10 and is the shape of contour lines representing a constant intensity. A multi-point beam refers to a beam whose outer shape is separated into two or more. Multiple beams separated from each other are also included in the multipoint beam when they are superposed by the use of an optical system. In FIG. 8 shown below, another example of intensity distribution adjustment will be described.

FIG. 8 is a diagram for explaining another example of intensity distribution adjustment by the intensity distribution adjusting unit shown in FIG. In the first example shown in FIG. 8, the intensity distribution adjusting unit 19 converts the laser beam 10 into five beams 10a, 10b, 10c, 10d, and 10e which are multipoint beams. In the workpiece, a part of the spots 50a, 50b, 50c, 50d, 50e of each beam is superposed on each other. The intensity distribution adjusting unit 19 adjusts the intensity distribution by appropriately adjusting the intensity of each beam 10a, 10b, 10c, 10d, 10e.

In the second example shown in FIG. 8, the beam 10f is a laser beam 10 that reciprocates in the X-axis direction. The intensity distribution adjusting unit 19 can obtain the same effect as the case of converting the laser beam 10 into a linear beam outer shape by irradiating the beam 10f in a linear region long in the X-axis direction with respect to the Y-axis direction. can. By moving the laser beam 10 in at least one of the X-axis direction and the Y-axis direction, the intensity distribution adjusting unit 19 can obtain the same effect as in the case of converting the laser beam 10 into an arbitrary beam shape. Further, the intensity distribution adjusting unit 19 can adjust the intensity distribution in the region irradiated by the beam 10f by changing the mode of moving the spot 50f of the beam 10f. Such movement of the laser beam 10 using at least one of the galvano scanner 33X and the galvano scanner 33Y may be referred to as a raster scan in the following description.

In the third example shown in FIG. 8, the intensity distribution adjusting unit 19 converts the laser beam 10 into two beams 10h and 10g having different sizes of beam outer shapes. The intensity distribution adjusting unit 19 reflects the beam 10g having the smaller beam outer shape of the two beams 10h and 10g by the mirror 38, and includes the spot 50g of the beam 10g in the spot 50h of the beam 10h. Superimposing the spot of one beam on the spot of another beam in this way may be referred to as a spot-in-spot in the following description.

The intensity of the region where the spots 50g overlap in the spot 50h is higher than the region other than the region where the spots 50g overlap in the spot 50h. In the third example, the intensity distribution adjusting unit 19 adjusts the intensity distribution by using the spot-in-spot. Further, the intensity distribution adjusting unit 19 can change the intensity distribution in the spot 50h without changing the outer shape of the spot 50h by moving the mirror 38. The intensity distribution adjusting unit 19 may realize a spot-in-spot by using a prism instead of the mirror 38.

In this way, the intensity distribution adjusting unit 19 can adjust the intensity distribution using any one of a multi-point beam, a raster scan, or a spot-in-spot. The intensity distribution adjusting unit 19 can convert the intensity distribution of the laser beam 10 in the workpiece into various intensity distributions. The intensity distribution adjusting unit 19 may adjust the intensity distribution by combining two or more of the multi-point beam, the raster scan, and the spot-in-spot. In addition, the intensity distribution adjusting unit 19 may adjust the intensity distribution by using an aspherical lens, optical interference, zoom optics, a beam shaper, an image rotator, or the like.

By such adjustment in the intensity distribution adjusting unit 19, the additional manufacturing apparatus 100 can freely change the intensity distribution of the laser beam 10 in the workpiece without lowering the laser output. The addition manufacturing apparatus 100 can optimize the intensity distribution without lowering the processing speed by not lowering the laser output. The addition manufacturing apparatus 100 can realize high-speed machining by not reducing the machining speed.

According to the first embodiment, the additional manufacturing apparatus 100 adjusts the strength distribution based on the design data 26 by the strength distribution adjusting unit 19, thereby reducing the excess or deficiency of the amount of heat input when melting the filler metal. Can be done. As a result, the addition manufacturing apparatus 100 has the effect of being able to manufacture the modeled object with high accuracy.

Embodiment 2.
In the second embodiment, a case where the intensity of the laser beam 10 is adjusted to be increased in a region where the amount of heat input is insufficient in a single wire bead will be described. FIG. 9 is a diagram for explaining the operation of the addition manufacturing apparatus according to the second embodiment. FIG. 10 is a first diagram for explaining the adjustment of the intensity distribution in the second embodiment. FIG. 11 is a second diagram for explaining the adjustment of the intensity distribution in the second embodiment. In the second embodiment, the same components as those in the first embodiment are designated by the same reference numerals, and the configurations different from those in the first embodiment will be mainly described.

In the second embodiment, the strength distribution calculation unit 45 estimates the heat input amount of the workpiece at the time of forming the bead 8 based on the design data 26, the set processing conditions, and the set strength distribution, and the heat input amount. Change the intensity distribution based on.

When forming the bead 8 which is a line bead, the additional manufacturing apparatus 100 moves the machining head 3 so that the irradiation position of the laser beam 10 is aligned with the machining start position x1. The additional manufacturing apparatus 100 turns on the output of the laser beam 10. At the same time, as shown in FIG. 11, the additional manufacturing apparatus 100 starts feeding the wire 5 at a constant supply amount W and moving the machining head 3 at a constant feed rate F. The addition manufacturing apparatus 100 moves the machining head 3 along the movement path to x3, which is the machining end position. x2 is a position on the movement path and is a position between x1 and x3. The processing point 9 is assumed to move in the positive direction in the X-axis direction.

A molten pool is formed by melting the workpiece at the processing point 9. As the machining point 9 moves, the molten pool at the position where the machining point 9 has passed solidifies, and the workpiece melts at the destination of the machining point 9, so that the molten pool becomes as the machining progresses. The position moves. Wires 5 are sequentially supplied to the molten pool. The bead 8 is formed by solidifying the molten pool and the melt of the wire 5 at the position where the processing point 9 has passed.

When the machining point 9 reaches x3, the additional manufacturing apparatus 100 stops the machining head 3. At the same time, the addition manufacturing apparatus 100 turns off the output of the laser beam 10 and stops the feeding of the wire 5. The addition manufacturing apparatus 100 pulls out the wire 5 from the molten pool by pulling back the wire 5 as needed.

FIG. 9 shows a graph showing the amount of heat input to the work piece before the strength distribution is changed by the strength distribution adjusting unit 19, and a graph showing the amount of heat input to the work piece after the strength distribution is changed by the strength distribution adjusting unit 19. Is shown. As shown in FIG. 10, the beam shape 51 in the workpiece is a square having a side length of d. The intensity distribution before the change is D1. The amount of heat input is the amount of heat in the unit length in the X-axis direction of the workpiece. The amount of heat input is expressed as P / F by dividing the beam output P by the feed rate F. The unit of heat input is J / mm.

In the case of moving the laser beam 10 having the intensity distribution D1 from x1 to x3, in x1, the movement of the processing head 3 is started at the same time when the output of the laser beam 10 is turned on. In the irradiation region of the laser beam 10 when the center of the laser beam 10 is x1, the amount of heat input increases as the portion closer to x2. In the portion of the irradiation region where the amount of heat input is small, the amount of the molten filler material added is small, while the excess filler material that is not added is added to the portion closer to x2 where the amount of heat input is large. Therefore, in the irradiation region of the laser beam 10 at the start of processing, a shape error is likely to occur due to an increase in the amount of filler material added in the portion closer to x2. In the irradiation region of the laser beam 10 when the center of the laser beam 10 is x3, the amount of heat input increases toward the portion closer to x2, so that the excess filler material is added to the portion closer to x2. Even in the irradiation region of the laser beam 10 at the end of processing, a shape error is likely to occur due to an increase in the amount of filler material added in the portion closer to x2. Therefore, even when the bead 8 is formed based on the design data 26, the set machining conditions, and the set strength distribution, at the end of the bead 8 which is the machining start position and the end which is the machining end position. , Shape accuracy tends to decrease.

The intensity distribution calculation unit 45 estimates the amount of heat input and calculates the amount of heat input that is insufficient for the amount of heat input required to form the bead 8 having a desired shape. The intensity distribution calculation unit 45 obtains an intensity distribution that can compensate for the shortage of heat input in the region where the shortage of heat input occurs. In this way, the intensity distribution calculation unit 45 changes the intensity distribution based on the estimated heat input amount.

For example, in the irradiation region of the laser beam 10 when the center of the laser beam 10 reaches x3, the amount of heat input corresponding to A1 shown in FIG. 9 is insufficient. The intensity distribution calculation unit 45 obtains an intensity distribution D3 capable of supplementing the amount of heat corresponding to A1 for the region. The amount of heat required to make up for the shortage of heat input is (P / F) × d × (1 /) by multiplying P / F, which is the amount of heat input, by d, which is the width of the beam shape 51 in the X-axis direction. 2) = (P × d) / (2 × F) is calculated. Since x3 is the machining end position, the strength distribution calculation unit 45 estimates that the amount of heat input is smaller toward the plus side in the X-axis direction in the region. Based on this estimation, the intensity distribution calculation unit 45 obtains an intensity distribution D3 such that the intensity increases toward the plus side in the X-axis direction. In this way, the intensity distribution calculation unit 45 estimates the distribution of the amount of heat input in the region, and obtains the intensity distribution D3 that matches the estimated distribution.

Assuming that the intensity of the laser beam 10 in the region is P'and the irradiation time is s, the irradiation time required to compensate for the shortage of heat input is s = (1 / P') × (P × d) / (2 ×). It is calculated as F). When the intensity of the laser beam 10 in the region remains P, that is, when P'= P, the irradiation time is calculated as s = d / (2 × F).

For the irradiation region of the laser beam 10 when the center of the laser beam 10 is x1, the required amount of heat and the irradiation time can be calculated as in the case when the center of the laser beam 10 reaches x3. can. Since x1 is the machining start position, the strength distribution calculation unit 45 estimates that the amount of heat input is smaller toward the minus side in the X-axis direction in the region. Based on this estimation, the intensity distribution calculation unit 45 obtains an intensity distribution D2 such that the intensity increases toward the minus side in the X-axis direction. In this way, the intensity distribution calculation unit 45 estimates the distribution of the amount of heat input in the region, and obtains the intensity distribution D2 that matches the estimated distribution.

As shown in FIG. 11, the intensity distribution calculation unit 45 changes the intensity distribution at x1 to D2 at the time T1 including the timing when the laser beam 10 starts moving from x1. The intensity distribution adjusting unit 19 adjusts the intensity distribution to D2. The intensity distribution calculation unit 45 changes the intensity distribution at the time T3 including the timing when the laser beam 10 reaches x3 to D3. The intensity distribution adjusting unit 19 adjusts the intensity distribution to D3. The intensity distribution adjusting unit 19 does not adjust the intensity distribution in the time T2 until the laser beam 10 moves from x1 to x3, and leaves the intensity distribution as D1.

As described above, the intensity distribution calculation unit 45 relates to the region irradiated by the laser beam 10 when the processing point 9 is x1 and the region irradiated by the laser beam 10 when the position of the processing point 9 is x3. The amount of heat input is estimated and the intensity distribution is changed based on the estimated amount of heat input. As a result, the addition manufacturing apparatus 100 can make the amount of heat input constant from x1 to x3. The addition manufacturing apparatus 100 can form a bead 8 having high shape accuracy from x1 to x3. The additional manufacturing apparatus 100 can improve the shape accuracy of the bead 8 at the machining start position and the machining end position, so that the modeled object can be manufactured with high accuracy.

In the example shown in FIG. 11, the intensity distribution calculation unit 45 has an intensity distribution of D2 when the center of the laser beam 10 is x1 and a intensity distribution of D3 when the center of the laser beam 10 is x3. Adjust the intensity distribution. The intensity distribution calculation unit 45 is not limited to adjusting the intensity distribution by such a method. Here, a modified example of the strength distribution adjustment in the second embodiment will be described.

FIG. 12 is a diagram for explaining a modified example of the strength distribution adjustment in the second embodiment. Here, two variations of the intensity distribution adjustment will be described. FIG. 12A schematically shows the change in the intensity distribution due to the intensity distribution adjustment according to the modified example 1. FIG. 12B schematically shows the change in the intensity distribution due to the intensity distribution adjustment according to the modified example 2. In FIGS. 12A and 12B, the laser beam 10 moves while the intensity distribution of the laser beam 10 changes until the laser beam 10 is moved from x2 to x3 and the laser beam 10 is turned off. Represents. In FIGS. 12 (a) and 12 (b), the vertical axis “t” represents time.

In the first modification shown in FIG. 12A, the amount of heat input in the irradiation region when the center of the laser beam 10 reaches x3 by changing the intensity distribution before the center of the laser beam 10 reaches x3. Make up for the shortage. When the laser beam 10 goes from x2 to x3, the intensity distribution of the laser beam 10 is D1. The intensity distribution calculation unit 45 changes the intensity distribution from D1 in the period Δta from the timing when the center of the irradiation region reaches the position of x3-d until the center of the irradiation region reaches x3. The intensity distribution calculation unit 45 changes the intensity distribution so that the intensity increases toward the plus side in the X-axis direction in the region where x3 is the center and the width is d. At the timing when the center of the laser beam 10 reaches x3, the addition manufacturing apparatus 100 stops the feeding of the wire 5 and the irradiation of the laser beam 10. The addition manufacturing apparatus 100 compensates for the lack of heat input by adjusting the intensity distribution in this way.

When the laser beam 10 starts moving from x1, the intensity distribution calculation unit 45 changes the intensity distribution in the same manner as when the laser beam 10 reaches x3. The intensity distribution calculation unit 45 changes the intensity distribution so that the intensity increases toward the minus side in the X-axis direction in the region where x1 is the center and the width is d. After that, the intensity distribution of the laser beam 10 is changed to D1, and the laser beam 10 moves from x1 to x2. According to the first modification, the addition manufacturing apparatus 100 can prevent the shape accuracy from being lowered at the end of the bead 8 at x1 and the end at x3 by adjusting the intensity distribution at x1 and x3. In the case of the modification 1, the machining time can be shortened as compared with the case of the strength distribution adjustment according to the example shown in FIG.

In the second modification shown in FIG. 12B, the width of the laser beam 10 is reduced and the movement of the laser beam 10 is continued from the time when the center of the laser beam 10 reaches x3, so that the amount of heat input is insufficient. compensate. When the laser beam 10 goes from x2 to x3, the intensity distribution of the laser beam 10 is D1. At the timing when the center of the irradiation region reaches x3, the addition manufacturing apparatus 100 stops the feeding of the wire 5. The movement of the laser beam 10 is continued in the period Δtb from the timing when the center of the irradiation region reaches the position of x3 until the irradiation of the laser beam 10 is stopped. The intensity distribution calculation unit 45 changes the intensity distribution by changing the width of the irradiation region while the movement of the laser beam 10 is continued in the period Δtb. The intensity distribution calculation unit 45 makes adjustments to gradually reduce the width of the irradiation region in the X-axis direction so that the irradiation region does not protrude to the plus side in the X-axis direction from the position of x3 + 2 / d. The addition manufacturing apparatus 100 continues the movement of the laser beam 10 while gradually reducing the width of the irradiation region, and then stops the irradiation of the laser beam 10. The addition manufacturing apparatus 100 compensates for the lack of heat input by adjusting the intensity distribution in this way.

The intensity distribution calculation unit 45 changes the intensity distribution in the same manner as after the laser beam 10 reaches x3 even before the laser beam 10 starts moving from x1. The addition manufacturing apparatus 100 starts irradiating the laser beam 10 on the minus side in the X-axis direction with respect to x1 to move the laser beam 10. At the start of irradiation of the laser beam 10, the width of the irradiation region in the X-axis direction is smaller than d. The intensity distribution calculation unit 45 gradually increases the width of the irradiation region so that the width of the irradiation region in the X-axis direction becomes d when the center of the laser beam 10 reaches x1. The intensity distribution calculation unit 45 adjusts the width of the irradiation region so that the irradiation region does not protrude to the minus side in the X-axis direction from the position of x1-2 / d. When the center of the laser beam 10 reaches x1, the intensity distribution is changed to D1 and the laser beam 10 moves from x1 to x2. According to the second modification, the addition manufacturing apparatus 100 can prevent the shape accuracy from being lowered at the end of the bead 8 at x1 and the end at x3 by adjusting the intensity distribution at x1 and x3. In the case of the second modification, the intensity distribution can be adjusted without changing the energy density of the laser beam 10.

According to the second embodiment, the addition manufacturing apparatus 100 estimates the heat input amount of the workpiece at the time of forming the bead 8, and changes the strength distribution based on the heat input amount. The addition manufacturing apparatus 100 can reduce the deviation of the shape from the three-dimensional shape shown in the design data 26 by reducing the shortage of the amount of heat input. As a result, the addition manufacturing apparatus 100 has the effect of being able to manufacture the modeled object with high accuracy.

Embodiment 3.
In the third embodiment, a case where the intensity of the laser beam 10 is adjusted to be increased in a region where the amount of heat input is insufficient in the curved line bead will be described. FIG. 13 is a diagram for explaining the operation of the addition manufacturing apparatus according to the third embodiment. FIG. 14 is a diagram for explaining the adjustment of the intensity distribution in the third embodiment. In the third embodiment, the same components as those in the first or second embodiment are designated by the same reference numerals, and the configurations different from those in the first or second embodiment will be mainly described.

In the third embodiment, the strength distribution calculation unit 45 estimates the heat input amount of the workpiece at the time of forming the bead 8 based on the design data 26, the set processing conditions, and the set strength distribution, and the heat input amount. Change the intensity distribution based on.

In the third embodiment, the case where the addition manufacturing apparatus 100 forms an arcuate bead 8 having a radius R is taken as an example. The beam shape 51 in the workpiece is a square having a side length d, as in the case shown in FIG. The intensity distribution before the change is D1. The addition manufacturing apparatus 100 moves the machining point 9 at a constant feed rate along the arcuate movement path.

When the laser beam 10 is moved along the arc, the amount of heat input increases toward the inner peripheral side and decreases toward the outer peripheral side in the region through which the beam shape 51 passes. That is, as shown in FIG. 14, in the end xr1 on the inner peripheral side of the region through which the beam shape 51 passes, the amount of heat input is larger than that in the radial center of the region. Further, in the end xr2 on the outer peripheral side of the region through which the beam shape 51 passes, the amount of heat input is smaller than that in the radial center of the region.

The ratio of the amount of heat input at each of the end xr2, the center, and the end xr1 can be expressed by the ratio of the lengths of the arcs. That is, the ratio of the amount of heat input at each of the end xr2, the center, and the end xr1 is expressed as 2π (R + d / 2): 2πR: 2π (R−d / 2).

The intensity distribution calculation unit 45 estimates the amount of heat input in the region through which the beam shape 51 passes, and calculates the amount of heat input that is insufficient for the amount of heat input required to form the bead 8 having a desired shape. Further, the intensity distribution calculation unit 45 obtains an intensity distribution that can compensate for the excess or deficiency of the amount of heat input. In this way, the intensity distribution calculation unit 45 changes the intensity distribution based on the estimated heat input amount.

The intensity distribution calculation unit 45 changes the intensity distribution on the inner peripheral side of the region through which the beam shape 51 passes so as to reduce the excess amount of heat input. The intensity distribution calculation unit 45 changes the intensity distribution on the outer peripheral side of the region through which the beam shape 51 passes so as to compensate for the shortage of the amount of heat input. Based on the determined bead shape, the intensity distribution calculation unit 45 estimates that the inner peripheral side has a larger amount of heat input and the outer peripheral side has a smaller amount of heat input. Based on this estimation, the intensity distribution calculation unit 45 obtains an intensity distribution D4 such that the intensity is lower toward the inner peripheral side and higher toward the outer peripheral side. In this way, the intensity distribution calculation unit 45 estimates the distribution of the amount of heat input in the region, and obtains the intensity distribution D4 that matches the estimated distribution.

The addition manufacturing apparatus 100 can make the amount of heat input constant from the inner peripheral side to the outer peripheral side of the region through which the beam shape 51 passes. The addition manufacturing apparatus 100 can form a bead 8 having high shape accuracy from the inner peripheral side to the outer peripheral side. The additional manufacturing apparatus 100 can improve the shape accuracy of the bead 8 at the machining start position and the machining end position, so that the modeled object can be manufactured with high accuracy. According to the third embodiment, the additional manufacturing apparatus 100 can manufacture a modeled object having high shape accuracy without lowering the processing speed.

Embodiment 4.
In the fourth embodiment, a case where the strength distribution is adjusted based on the result of measuring the molten state of the workpiece and the molten state of the filler metal will be described. FIG. 15 is a diagram for explaining the operation of the addition manufacturing apparatus according to the fourth embodiment. FIG. 15 shows a state in which the wire 5, the wire feeder 7, and the bead 8 are observed from the processing head 3 side when the bead 8 is formed. FIG. 15 shows the bead 8 which is a work piece. In the fourth embodiment, the same components as those in the first to third embodiments are designated by the same reference numerals, and the configurations different from those in the first to third embodiments will be mainly described.

The intensity distribution adjusting unit 19 superimposes the spot 52a of one beam on the spot 52b of the other beam. That is, the intensity distribution adjusting unit 19 adjusts the intensity distribution by using the spot-in-spot. The outer shape of the spot 52a is an ellipse having a long axis in the X-axis direction. The spot 52a illuminates the tip of the wire 5. The outer shape of the spot 52b is rectangular. The spot 52b irradiates the tip of the wire 5 and the periphery of the tip of the wire 5.

Let Pa be the intensity of the laser beam 10 capable of maintaining the molten state of the wire 5, and Pb be the intensity of the laser beam 10 capable of maintaining the molten state of the workpiece. In order to maintain the melted state of the workpiece and the melted state of the wire 5, the strength distribution adjusting unit 19 adjusts the strength of the spot 52a to Pa and the strength of the spot 52b to Pb, respectively.

The strength distribution adjusting unit 19 acquires the temperature value of the wire 5 measured by the sensor unit 20 as the measurement result of the molten state of the wire 5. The intensity distribution adjusting unit 19 acquires the temperature value of the workpiece measured by the sensor unit 20 as the measurement result of the molten state of the workpiece. The intensity distribution adjusting unit 19 may estimate the molten state of the wire 5 based on the melting point of the wire 5, the absorption rate of the laser beam 10 in the wire 5, and the heat capacity of the wire 5. The intensity distribution adjusting unit 19 may estimate the molten state of the workpiece based on the melting point of the workpiece, the absorption rate of the laser beam 10 in the workpiece, and the heat capacity of the workpiece.

The intensity distribution adjusting unit 19 maintains the molten state of the wire 5 and the molten state of the workpiece by individually controlling the intensity of the laser beam 10 in the wire 5 and the intensity of the laser beam 10 in the workpiece. be able to. The additional manufacturing apparatus 100 can appropriately melt both the wire 5 and the workpiece even if the wire 5 and the workpiece have different physical properties such as reflectance. Further, the additional manufacturing apparatus 100 can appropriately melt both the wire 5 and the workpiece even in a situation where the energy density in the workpiece is lowered, such as when the workpiece is inclined. can. According to the fourth embodiment, the addition manufacturing apparatus 100 can stably melt the filler metal and the workpiece, so that the shaped object can be manufactured with high accuracy.

Embodiment 5.
In the fifth embodiment, the modification of the strength distribution for manufacturing a model having an arbitrary internal structure will be described. FIG. 16 is a diagram for explaining the operation of the addition manufacturing apparatus according to the fifth embodiment. FIG. 16 shows three examples of the formation of point beads. For each of the three examples, the beam shape in the X-axis direction and the Y-axis direction and the side surface of the point bead are shown. In the fifth embodiment, the same components as those in the first to fourth embodiments are designated by the same reference numerals, and the configurations different from those in the first to fourth embodiments will be mainly described.

The bead 53a in the first example is a point bead formed by irradiating a laser beam 10 having a circular beam outer shape. The intensity distribution of the laser beam 10 is D10, which is the intensity distribution when the intensity distribution adjusting unit 19 does not change the intensity distribution. FIG. 16 shows how 6 × 4 beads 53a are formed on the base material 11.

The addition manufacturing apparatus 100 can arrange a plurality of beads 53a without gaps by appropriately adjusting the spacing between the beads 53a. The addition manufacturing apparatus 100 can manufacture a solid block shape by stacking a plurality of layers of a plurality of beads 53a arranged without gaps.

In the second example, the bead 53b and the bead 53c are point beads having the same rectangular shape as each other. When the bead 53b and the bead 53c are viewed from the processing head 3, the bead 53b is a bead 53c rotated by 45 degrees. The beam outer shape when the bead 53b is formed is a beam outer shape rotated by 45 degrees when the bead 53c is formed. The intensity distribution adjusting unit 19 changes D11 and D12 so that the intensity distribution D11 when the bead 53b is formed is rotated by 45 degrees from the intensity distribution D12 where the bead 53c is formed.

The distance between the beads 53b and the distance between the beads 53c are the same as each other. While the beads 53c are arranged without a gap, a gap is formed between the beads 53b. Therefore, the density at which the plurality of beads 53b are arranged is lower than the density at which the plurality of beads 53c are arranged. In this way, the intensity distribution adjusting unit 19 can manufacture a modeled object having different densities of materials in the internal structure by rotating the outer shape of the beam by changing the intensity distribution.

In the third example, the bead 53d and the bead 53e are point beads having the same elliptical shape as each other. When the bead 53d and the bead 53e are viewed from the processing head 3, the bead 53e is obtained by rotating the bead 53d by 45 degrees. The beam outer shape when the bead 53e is formed is a beam outer shape rotated by 45 degrees when the bead 53d is formed. The intensity distribution adjusting unit 19 changes D13 and D14 so that the intensity distribution D13 when the bead 53d is formed is rotated by 45 degrees from the intensity distribution D14 in which the bead 53e is formed.

The bead 53d and the bead 53e are alternately arranged at regular intervals in each of the X-axis direction and the Y-axis direction. By arranging the plurality of beads 53d and the plurality of beads 53e side by side, a gap surrounded by the two beads 53d and the two beads 53e is formed. The addition manufacturing apparatus 100 can manufacture a model having a hollow structure by stacking a plurality of layers of the beads 53d and the beads 53e.

According to the fifth embodiment, the additional manufacturing apparatus 100 changes the beam outer shape by adjusting the intensity distribution by the intensity distribution adjusting unit 19. The addition manufacturing apparatus 100 can manufacture a model having an arbitrary internal structure by changing the outer shape of the beam.

Embodiment 6.
In the sixth embodiment, an example of adjusting the strength distribution based on the temperature distribution of the workpiece will be described. FIG. 17 is a first diagram for explaining the operation of the addition manufacturing apparatus according to the sixth embodiment. FIG. 18 is a second diagram for explaining the operation of the addition manufacturing apparatus according to the sixth embodiment. FIG. 17 shows a state in which the bead 8 and the molten pool 55 at the time of forming the bead 8 are observed from the processing head 3 side. In FIG. 17, the wire 5 supplied to the molten pool 55 is not shown. In the sixth embodiment, the same components as those in the first to fifth embodiments are designated by the same reference numerals, and the configurations different from those in the first to fifth embodiments will be mainly described.

In the sixth embodiment, the outer shape of the beam is a circle having a diameter of d. In FIG. 17, the machining point 9 is moving in the positive direction in the X-axis direction. The thermometer provided in the sensor unit 20 measures the temperature distribution of the workpiece on the first measurement line 56A. The first measurement line 56A is a line segment that passes through a position on the movement path and is a line segment that is perpendicular to the movement path. The intersection of the first measurement line 56A and the movement path is a position ahead of the current processing point 9.

The thermometer is fixed to the processing head 3. The first measurement line 56A moves to the front of the movement path with the movement of the machining point 9. If the time from the passage of the first measurement line 56A through the position on the workpiece to the passage of the machining point 9 through the position is known, the distance between the machining point 9 and the first measurement line 56A is , It may or may not be fixed. The intensity distribution adjusting unit 19 adjusts the intensity distribution of the laser beam 10 based on the temperature measurement result in the first measurement line 56A.

FIG. 18 shows the distribution of the measured values, which are the measurement results by the thermometer, the distribution of the converted values for converting the intensity distribution, and the intensity distribution after the conversion based on the converted values. The distribution of the measured values shown in FIG. 18 is the distribution in the Y-axis direction. The intensity distribution calculation unit 45 obtains a converted value whose magnitude is opposite to the measured value in the temperature value distribution, and changes the intensity distribution based on the converted value.

Assuming that the distribution of the measured values of the temperature in the first measurement line 56A is T (y), the target temperature of the molten pool 55 is α, and the coefficient is β, the intensity distribution for obtaining the molten pool 55 at the target temperature is β {. It is expressed as α-T (y)}. T (y) represents a measured value for each position in the Y-axis direction. {Α-T (y)} represents the difference between the target temperature and the measured value. When the processing point 9 reaches a certain position through which the first measurement line 56A has passed, the intensity distribution adjusting unit 19 adjusts the intensity distribution of the laser beam 10 to β {α—T (y)}.

β is a coefficient mainly determined by the absorption rate of the laser beam 10 in the workpiece and the heat capacity of the workpiece. The value of β is calculated. The value of β may be corrected based on the result of trial machining.

According to the sixth embodiment, the addition manufacturing apparatus 100 can make the temperature distribution in the molten pool 55 uniform by adjusting the intensity distribution of the laser beam 10 based on the temperature distribution of the workpiece. The addition manufacturing apparatus 100 can improve the shape accuracy of the bead 8, and can manufacture a modeled object having high shape accuracy.

The additional manufacturing apparatus 100 may sequentially correct each value of α and β based on the temperature measurement result in the second measurement line 56B shown in FIG. In this case, the thermometer provided in the sensor unit 20 measures the temperature distribution of the workpiece on the second measurement line 56B. The second measurement line 56B is a line segment that passes through a position on the movement path and is a line segment that is perpendicular to the movement path. The intersection of the second measurement line 56B and the movement path is a position after the current processing point 9. The addition manufacturing apparatus 100 can manufacture a modeled object having high shape accuracy by correcting α and β.

Embodiment 7.
In the seventh embodiment, a case where the strength distribution is adjusted based on the shape of the workpiece will be described. FIG. 19 is a first diagram for explaining the operation of the addition manufacturing apparatus according to the seventh embodiment. FIG. 20 is a second diagram for explaining the operation of the addition manufacturing apparatus according to the seventh embodiment. In the seventh embodiment, the same components as those in the first to sixth embodiments are designated by the same reference numerals, and the configurations different from those in the first to sixth embodiments will be mainly described.

The two beads 8 that are the workpieces are arranged in the X-axis direction. FIG. 19 shows a state when the bead 8 is formed in the recess 58 between the two beads 8. In the seventh embodiment, the outer shape of the spot is a square having a side length of d. The intensity distribution before the change is D1 as in the case shown in FIG.

In FIG. 19, the machining point 9 moves in the positive direction in the Y-axis direction. The shape measuring instrument provided in the sensor unit 20 measures the height distribution of the workpiece on the measuring line 59. The height is the height in the Z-axis direction. The measurement line 59 is a line segment that passes through a position on the movement path and is a line segment that is perpendicular to the movement path. The intersection of the measurement line 59 and the movement path is a position ahead of the current processing point 9. The intensity distribution adjusting unit 19 adjusts the temperature distribution of the laser beam 10 based on the height measurement result in the measurement line 59.

FIG. 20 shows the shape of the cross section of the workpiece on the measurement line 59, the distribution of the measured values as the measurement result of the height, the distribution of the differential values as the result of differentiating the measured values, and the absolute value of the differential values. The values and the intensity distribution after conversion based on the absolute value are shown. The distribution of the measured values shown in FIG. 20 is the distribution in the X-axis direction.

Let H (x) be the distribution of the measured values on the measurement line 59. H (x) represents a measured value for each position in the Y-axis direction. In order to make the amount of heat input in the work piece uniform, it is necessary to increase the energy supplied as the inclination of the surface of the work piece with respect to the X-axis increases. Such an inclination is expressed as dH (x) / dx. The derivative value shown in FIG. 20 represents the distribution of the inclination on the surface of the workpiece. Assuming that the angle between the X-axis and the surface of the workpiece is θ, θ = arctan | dH (x) / dx | holds. The required intensity distribution can be expressed as D1 (x) / cos (θ), which is the product of D1 (x) and 1 / cos (θ). The intensity distribution adjusting unit 19 adjusts the intensity distribution of the laser beam 10 to D1 (x) / cos (θ) by setting θ = arctan | dH (x) / dx |.

According to the seventh embodiment, the addition manufacturing apparatus 100 can make the amount of heat input in the workpiece uniform by adjusting the intensity distribution of the laser beam 10 based on the shape of the workpiece. The addition manufacturing apparatus 100 can improve the shape accuracy of the bead 8, and can manufacture a modeled object having high shape accuracy. The addition manufacturing apparatus 100 can reduce a decrease in wettability due to a partial shortage of heat input. As a result, the addition manufacturing apparatus 100 can suppress a decrease in processing accuracy and the generation of voids.

Embodiment 8.
In the eighth embodiment, how to select an intensity distribution suitable for the design data 26 will be described. In the eighth embodiment, it is assumed that the outer shape of the laser beam 10 can be selected from two, a circular shape and a rectangular shape. In the eighth embodiment, the intensity distribution adjusting unit 19 adjusts the intensity distribution based on the shape specified by the design data 26. In the eighth embodiment, the same components as those in the first to seventh embodiments are designated by the same reference numerals, and the configurations different from those in the first to seventh embodiments will be mainly described.

FIG. 21 is a diagram for explaining the first bead formed in the eighth embodiment. FIG. 22 is a diagram for explaining the second bead formed in the eighth embodiment. The first bead 60a shown in FIG. 21 is a line bead formed by using a laser beam 10 having a circular beam outer shape. The second bead 60b shown in FIG. 22 is a line bead formed by using the laser beam 10 having a rectangular beam outer shape.

FIG. 23 is a first diagram for explaining a modeled object manufactured by using the first bead in the addition manufacturing apparatus according to the eighth embodiment. FIG. 24 is a second diagram for explaining a modeled object manufactured by using the first bead in the addition manufacturing apparatus according to the eighth embodiment. In the eighth embodiment, a case where a modeled object having a length in the X-axis direction of L, a width in the Y-axis direction of M, and a height in the Z-axis direction of H will be described.

Let XL1 be the distance from the machining start position to the machining end position when forming the first bead 60a. Of the first bead 60a, both the first end on the machining start side and the second end on the machining end side are hemispherical. Assuming that the radius of the hemisphere at the first end is a11 and the radius of the hemisphere at the second end is a12, the length of the first bead 60a in the X-axis direction is expressed as XL1 + a11 + a12. The width of the first bead 60a in the Y-axis direction is c1, and the height of the first bead 60a in the Z-axis direction is h1.

FIG. 23 shows a state when the four first beads 60a are formed and a product shape 61 shown in the three-dimensional shape information of the design data 26. Four first beads 60a are required to obtain an additional processing shape larger than the product shape 61. The portion of the additional processing shape that protrudes from the product shape 61 is removed by a cutting process that is a post-processing.

FIG. 24 shows the state when the first one of the four first beads 60a shown in FIG. 23 is formed. The length of the machining path 62, which is the movement path when the one first bead 60a is formed, is XL1, which is the same length as L. Of the first bead 60a, the portion having a length a11 on the first end side and the portion having a length a12 on the second end side are removed by cutting. The width c1 of the first bead 60a also includes a portion protruding from the product shape 61. The portion of the width c1 that protrudes from the product shape 61 is removed by cutting. The height h1 of the first bead 60a also includes a portion protruding from the product shape 61. The portion of the height h1 that protrudes from the product shape 61 is removed by cutting. The position of the machining path 62 in the Y-axis direction is determined so that c1 and h1 are the minimums.

Let Yp be the distance between the machining path 62 when the first bead 60a is formed and the machining path 62 when the second first bead 60a is formed. Yp is set so that the vertices of each of the two first beads 60a are at the same height as each other. The apex is the highest position in the Z-axis direction of the first beads 60a. Yp is calculated from the cross-sectional shape of the first bead 60a. Yp may be determined based on the result of trial machining. The movement path 63 is a path for moving the processing head 3 without processing. FIG. 24 shows a processing path 62 and a moving path 63 in the case of forming the four first beads 60a. The processing path 62 and the moving path 63 are determined by the path generation unit 42 shown in FIG.

As shown in FIG. 22, the distance from the machining start position to the machining end position when forming the second bead 60b is defined as XL2. Of the second beads 60b, both the first end on the machining start side and the second end on the machining end side are cubic. Assuming that the width in the X-axis direction of the cube portion at the first end is a21 and the width in the X-axis direction of the cube portion at the second end is a22, the length of the second bead 60b in the X-axis direction is expressed as XL2 + a21 + a22. To. The width of the second bead 60b in the Y-axis direction is c2, and the height of the second bead 60b in the Z-axis direction is h2.

FIG. 25 is a diagram for explaining a modeled object manufactured by using the second bead in the addition manufacturing apparatus according to the eighth embodiment. FIG. 25 shows the state when the three second beads 60b are formed and the product shape 61 shown in the three-dimensional shape information of the design data 26. Three second beads 60b are required to obtain an additional processing shape larger than the product shape 61.

The length of the machining path 62 when one second bead 60b is formed is shorter than the length of the machining path 62 when one first bead 60a is formed. That is, XL1> XL2 holds. Further, a11> a21, a12> a22, c1> c2, h1> h2 are established. That is, when comparing the case where the beam outer shape is circular and the case where the beam outer shape is rectangular, the volume of the material which is surplus with respect to the product shape 61 is smaller when the beam outer shape is rectangular. Further, when the additional processed shape is manufactured by the second bead 60b, the number of beads is smaller than that in the case where the additional processed shape is manufactured by the first bead 60a.

The intensity distribution calculation unit 45 shown in FIG. 2 evaluates modeling when the beam outer shape is circular and when the beam outer shape is rectangular. When the processing path 62 and the moving path 63 are determined by the path generation unit 42, the strength distribution calculation unit 45 evaluates the modeling based on the additional processing shape and the processing time. In the case of the example shown in FIGS. 23 to 25, the intensity distribution calculation unit 45 evaluates that the processing time can be shortened when the beam outer shape is rectangular as compared with the case where the beam outer shape is circular. The intensity distribution calculation unit 45 selects a rectangular beam outer shape in forming the product shape 61 based on the result of the evaluation of the processing time. In this way, the additional manufacturing apparatus 100 can select the optimum beam shape based on the design data 26.

FIG. 26 is a first diagram for explaining an example of selecting a beam shape according to the eighth embodiment. In the example shown in FIG. 26, the addition manufacturing apparatus 100 uses a laser beam 10 having an equilateral triangle beam outer shape 64 to form a line bead in order to manufacture an equilateral triangle product shape 66. The additional manufacturing apparatus 100 forms an equilateral triangular point bead at the end point position 65 of the product shape 66.

FIG. 27 is a second diagram for explaining an example of selecting a beam shape according to the eighth embodiment. In the example shown in FIG. 27, the addition manufacturing apparatus 100 uses a laser beam 10 having a parallelogram beam outer shape 64 to form a line bead in order to manufacture a parallelogram product shape 66.

FIG. 28 is a third diagram for explaining an example of selecting a beam shape according to the eighth embodiment. In the example shown in FIG. 28, the addition manufacturing apparatus 100 uses a laser beam 10 having an elliptical beam outer shape 64 to form a line bead in order to manufacture an elliptical product shape 66. The addition manufacturing apparatus 100 forms an elliptical point bead at the end point position 65 of the product shape 66.

According to the eighth embodiment, the additional manufacturing apparatus 100 can reduce the surplus of the additional processing shape by optimizing the beam outer shape according to the three-dimensional shape specified by the design data 26. The processing time can be shortened. As a result, the addition manufacturing apparatus 100 can efficiently manufacture the modeled product.

Embodiment 9.
In the ninth embodiment, an example of learning a movement path, processing conditions, and an intensity distribution suitable for the design data 26 by a machine learning method will be described. FIG. 29 is a block diagram showing a configuration of an arithmetic unit included in the addition manufacturing apparatus according to the ninth embodiment. The arithmetic unit 70 performs an arithmetic operation for additional manufacturing. FIG. 29 shows the functional configuration of the arithmetic unit 70.

The arithmetic unit 70 has an input unit 41, a program generation unit 43, a data storage unit 46, an evaluation unit 47, a bead shape determination unit 48, and a shape estimation unit 49, similarly to the arithmetic unit 15 shown in FIG. The arithmetic unit 70 includes a learning device 71 that performs machine learning, an inference device 72 that performs operations for adjusting machining conditions and obtaining an intensity distribution, and a model storage unit 73 that stores the trained model.

The learning device 71 learns a movement path, processing conditions, and an intensity distribution suitable for modeling a three-dimensional shape specified by the design data 26, and generates a trained model. The inference device 72 infers the movement path, processing conditions, and intensity distribution suitable for modeling using the trained model. The inference device 72 is responsible for each function of the path generation unit 42, the machining condition adjustment unit 44, and the strength distribution calculation unit 45.

FIG. 30 is a block diagram showing a functional configuration of a learning device included in the addition manufacturing device according to the ninth embodiment. The learning device 71 has a data acquisition unit 74 and a model generation unit 75. The data acquisition unit 74 uses the design data 26, the machining program 27 used for the machining executed in the NC device 16, the machining condition information 28, the adjustment command 29 which is the intensity distribution information, and the measurement data 30. Acquire as training data.

The data acquisition unit 74 creates a data set including the three-dimensional shape information included in the design data 26, the movement path information included in the machining program 27, the machining condition information 28, and the adjustment command 29. The three-dimensional shape information is information representing the shape specified by the design data 26. The data acquisition unit 74 outputs the created data set to the model generation unit 75. Further, the data acquisition unit 74 outputs the measurement data 30 to the model generation unit 75.

The model generation unit 75 generates a trained model using the data set. The learning algorithm used by the model generation unit 75 may be any. As an example, the case where reinforcement learning is applied will be described. Reinforcement learning is that an action subject who is an agent in a certain environment observes the current state and decides an action to be taken. Agents get rewards from the environment by choosing actions and learn how to get the most rewards through a series of actions. Q-learning and TD-Learning are known as typical methods of reinforcement learning. For example, in the case of Q-learning, the action value table, which is a general update expression of the action value function Q (s, a), is expressed by the following equation (1). The action value function Q (s, a) represents the action value Q, which is the value of the action of selecting the action “a” under the environment “s”.

In the above equation (1), "st" represents the state of the environment at the time " _t ". “At” represents an action at time “ _t ”. The action "at" changes the state from " _st " to " _{st + 1} ". "R _{t + 1} " represents the reward obtained by changing the state from " _st + 1" to " _{st + 1} ". “Γ” represents a discount rate and satisfies 0 <γ ≦ 1. “Α” represents a learning coefficient and satisfies 0 <α ≦ 1. In the ninth embodiment, the _action "at" is the movement route information, the processing condition information 28, and the adjustment command 29. The state " _st " is the measurement data 30. The model generation unit 75 learns the best action “at” in the state “ _st ” at the time “ _t ”.

In the update formula expressed by the above formula (1), if the action value of the best action "a" at the time "t + 1" is larger than the action value Q of the action "a" executed at the time "t". , The action value Q is increased, and in the opposite case, the action value Q is decreased. In other words, the action value function Q (s, a) is updated so that the action value Q of the action “a” at the time “t” approaches the best action value at the time “t + 1”. As a result, the best behavioral value in one environment is sequentially propagated to the behavioral value in the previous environment.

The model generation unit 75 has a reward calculation unit 76 and a function update unit 77. The reward calculation unit 76 calculates the reward based on the difference between the shape data included in the measurement data 30 and the three-dimensional shape information. The shape data is data representing the shape of the bead 8, and represents the shape in the X-axis direction and the Y-axis direction and the height in the Z-axis direction. The function update unit 77 updates the function for determining the movement path, the processing condition, and the intensity distribution according to the reward calculated by the reward calculation unit 76. The function update unit 77 outputs the trained model created by updating the function to the model storage unit 73.

The reward calculation unit 76 calculates the reward “r” based on the difference between the shape data and the three-dimensional shape information. The reward calculation unit 76 increases the reward "r" when the difference becomes small. The reward calculation unit 76 increases the reward "r" by giving the reward value "1". The reward value is not limited to "1". Further, the reward calculation unit 76 reduces the reward "r" when the difference becomes large. The reward calculation unit 76 reduces the reward "r" by giving the reward value "-1". The reward value is not limited to "-1". When the design data 26 includes various variables that can be measured by the sensor unit 20, machining conditions, or constraints on the intensity distribution, the reward calculation unit 76 may reduce the reward if the constraints are not satisfied.

FIG. 31 is a flowchart showing a processing procedure of the learning device according to the ninth embodiment. A method of reinforcement learning for updating the action value function Q (s, a) will be described with reference to the flowchart of FIG. 31.

In step S21, the learning device 71 acquires learning data. In step S22, the learning device 71 calculates the reward. In step S23, the learning device 71 updates the action value function Q (s, a) based on the reward. In step S24, the learning device 71 determines whether or not the action value function Q (s, a) has converged. The learning device 71 determines that the action value function Q (s, a) has converged because the action value function Q (s, a) is not updated in step S23.

When it is determined that the action value function Q (s, a) has not converged (step S24, No), the learning device 71 returns the operation procedure to step S21. When it is determined that the action value function Q (s, a) has converged (steps S24, Yes), the learning device 71 ends the learning according to the procedure shown in FIG. 31. The learning device 71 may continue learning by returning the operation procedure from step S23 to step S21 without performing the determination in step S24. The model storage unit 73 stores the trained model which is the generated action value function Q (s, a).

FIG. 32 is a block diagram showing a functional configuration of an inference device included in the addition manufacturing device according to the ninth embodiment. The inference device 72 infers a movement path, processing conditions, and an intensity distribution suitable for the design data 26 based on the trained model. The inference device 72 has a data acquisition unit 78 and an inference unit 79.

The data acquisition unit 78 acquires the design data 26 as inference data. The data acquisition unit 78 outputs the design data 26 to the inference unit 79. By inputting the design data 26 into the trained model read from the model storage unit 73, the inference unit 79 infers the movement path, processing conditions, and intensity distribution suitable for the design data 26.

FIG. 33 is a flowchart showing the processing procedure of the inference device according to the ninth embodiment. In step S31, the inference device 72 acquires inference data in the data acquisition unit 78. In step S32, the inference device 72 inputs the inference data, which is the acquired data, to the trained model in the inference unit 79, and obtains the movement path, the processing conditions, and the intensity distribution. In step S33, the inference device 72 outputs information on the movement route, processing condition information 28, and adjustment command 29. As a result, the inference device 72 ends the process according to the procedure shown in FIG. 33.

In the ninth embodiment, the case where reinforcement learning is applied to the learning algorithm used by the learning device 71 has been described, but learning other than reinforcement learning may be applied to the learning algorithm. The learning device 71 may execute machine learning using a known learning algorithm other than reinforcement learning, for example, a learning algorithm such as deep learning, neural network, genetic programming, functional logic programming, or a support vector machine. good.

In the ninth embodiment, the learning device 71 is built in the additional manufacturing device 100. The learning device 71 is not limited to the device included in the addition manufacturing device 100, and may be an external device of the addition manufacturing device 100. The learning device 71 may be a device that can be connected to the addition manufacturing device 100 via a network. The learning device 71 may be a device existing on the cloud server.

The learning device 71 may learn the parameters according to the data set created for the plurality of additional manufacturing devices 100. The learning device 71 may acquire a data set from a plurality of additional manufacturing devices 100 used at the same site, or may acquire a data set from a plurality of additional manufacturing devices 100 used at different sites. Is also good. The data set may be collected from a plurality of additional manufacturing devices 100 that operate independently of each other at a plurality of sites. After starting the collection of the data set from the plurality of additional manufacturing devices 100, a new additional manufacturing device 100 may be added to the target for which the data set is collected. Further, after starting the collection of the data set from the plurality of additional manufacturing devices 100, a part of the plurality of additional manufacturing devices 100 may be excluded from the target for which the data set is collected.

The learning device 71 that has learned about one additional manufacturing device 100 may learn about other additional manufacturing devices 100 other than the additional manufacturing device 100. The learning device 71 that learns about the other additional manufacturing apparatus 100 can update the output prediction model by re-learning in the other additional manufacturing apparatus 100.

According to the ninth embodiment, the additional manufacturing apparatus 100 uses a trained model for inferring a movement path, a processing condition, and an intensity distribution suitable for the design data 26, and determines the movement path and determines the processing condition. Adjust and adjust the intensity distribution. The additional manufacturing apparatus 100 can reduce the excess or deficiency of the amount of heat input when melting the filler metal by adjusting the strength distribution and the processing conditions based on the design data 26. As a result, the addition manufacturing apparatus 100 can manufacture the modeled object with high accuracy. The additional manufacturing apparatus 100 can determine a movement path suitable for machining according to the design data 26, can reduce the surplus of the additional machining shape, and can shorten the machining time. As a result, the addition manufacturing apparatus 100 can efficiently manufacture the modeled product.

Next, the hardware configuration of the arithmetic units 15 and 70 according to the first to ninth embodiments will be described. FIG. 34 is a diagram showing a hardware configuration example of the arithmetic unit included in the addition manufacturing apparatus according to the first to ninth embodiments. FIG. 34 shows the hardware configuration when the functions of the arithmetic units 15 and 70 are realized by using the hardware for executing the program.

The arithmetic units 15 and 70 include a processor 81 that executes various processes, a memory 82 that is a built-in memory, a storage device 83 that stores information, and input of information to the arithmetic units 15 and 70 from the arithmetic units 15 and 70. It has an interface circuit 84 for outputting information of the above.

The processor 81 is a CPU (Central Processing Unit). The processor 81 may be a processing device, a microprocessor, a microcomputer, or a DSP (Digital Signal Processor). The memory 82 is a RAM (Random Access Memory), a ROM (Read Only Memory), a flash memory, an EPROM (Erasable Programmable Read Only Memory) or an EEPROM (registered trademark) (Electrically Erasable Programmable Read Only Memory).

The storage device 83 is an HDD (Hard Disk Drive) or an SSD (Solid State Drive). The program that causes the computer to function as the arithmetic units 15 and 70 is stored in the storage device 83. The processor 81 reads the program stored in the storage device 83 into the memory 82 and executes it.

The program may be stored in a storage medium that can be read by a computer system. The arithmetic units 15 and 70 may store the program recorded in the storage medium in the memory 82. The storage medium may be a portable storage medium that is a flexible disk, or a flash memory that is a semiconductor memory. The program may be installed in a computer system from another computer or server device via a communication network.

Each function of the path generation unit 42, the program generation unit 43, the machining condition adjustment unit 44, the intensity distribution calculation unit 45, the evaluation unit 47, the bead shape determination unit 48, the shape estimation unit 49, the learning device 71, and the inference device 72 is a processor. It is realized by the combination of 81 and software. Each of the functions may be realized by a combination of the processor 81 and the firmware, or may be realized by the combination of the processor 81, the software and the firmware. The software or firmware is written as a program and stored in the storage device 83. Each function of the data storage unit 46 and the model storage unit 73 is realized by using the storage device 83.

The interface circuit 84 receives a signal from an external device connected to the hardware. The external devices are an NC device 16, an intensity distribution controller 17, and a sensor unit 20. The function of the input unit 41 is realized by using the interface circuit 84.

The configuration shown in each of the above embodiments shows an example of the contents of the present disclosure. The configurations of each embodiment can be combined with other known techniques. The configurations of the respective embodiments may be appropriately combined. It is possible to omit or change a part of the configuration of each embodiment without departing from the gist of the present disclosure.

1 laser oscillator, 2 fiber cable, 3 processing head, 4 beam nozzle, 5 wire, 6 wire spool, 7 wire feeder, 8,53a, 53b, 53c, 53d, 53e bead, 9 processing point, 10 laser beam, 10a, 10b, 10c, 10d, 10e, 10f, 10g, 10h beam, 11 base material, 12,13 rotary stage, 14 XYZ stage, 15,70 arithmetic unit, 16 NC device, 17 intensity distribution controller, 18 laser output Controller, 19 Strength distribution adjuster, 20 Sensor unit, 21 Gas flow regulator, 22 Drive controller, 23 Head drive unit, 24 Wire feed drive unit, 25 Stage drive unit, 26 Design data, 27 Machining program, 28 Machining condition information, 29 adjustment command, 30 measurement data, 31 laser output command, 32 sync signal, 33X, 33Y galvano scanner, 34X, 34Y galvano mirror, 35X, 35Y galvano drive unit, 36 fθ lens, 37 paths, 38 mirrors, 41 Input unit, 42 Path generation unit, 43 Program generation unit, 44 Machining condition adjustment unit, 45 Strength distribution calculation unit, 46 Data storage unit, 47 Evaluation unit, 48 Bead shape determination unit, 49 Shape estimation unit, 50a, 50b, 50c, 50d, 50e, 50f, 50g, 50h, 52a, 52b spot, 51 beam shape, 55 molten pool, 56A first measurement line, 56B second measurement line, 58 recess, 59 measurement line, 60a first Bead, 60b second bead, 61,66 product shape, 62 machining path, 63 movement path, 64 beam outline, 65 end point position, 71 learning device, 72 inference device, 73 model storage section, 74,78 data acquisition section, 75 model generator, 76 reward calculation unit, 77 function update unit, 79 inference unit, 81 processor, 82 memory, 83 storage device, 84 interface circuit, 100 additional manufacturing unit.

Claims (13)

It is an additional manufacturing device that manufactures a model with the shape specified by the design data.
A supply unit that supplies the filler material to the work piece,
An irradiation unit that irradiates a beam that melts the supplied filler material,
An intensity distribution adjusting unit that adjusts the intensity distribution of the beam in the workpiece,
An additional manufacturing apparatus including a strength distribution calculation unit for obtaining the strength distribution by calculation based on the design data. It is provided with a shape estimation unit that estimates a three-dimensional shape formed based on the design data, the set processing conditions, and the set strength distribution.
The additional manufacturing apparatus according to claim 1, wherein the intensity distribution calculation unit changes the intensity distribution based on a difference between the shape shown in the design data and the estimated three-dimensional shape. The addition manufacturing apparatus manufactures the modeled product by forming a bead which is a solidified product of the melted filler metal.
The strength distribution calculation unit estimates the heat input amount of the work piece at the time of forming the bead based on the design data, the set processing conditions, and the set strength distribution, and based on the heat input amount. The additional manufacturing apparatus according to claim 1, wherein the intensity distribution is changed. It is provided with a measuring unit that measures the state of the workpiece or the state of the bead that is a solidified product of the melted filler metal and generates measurement data.
The additional manufacturing apparatus according to claim 1, wherein the intensity distribution calculation unit obtains the intensity distribution by an operation based on the design data and the measurement data. The additional manufacturing apparatus according to claim 1, wherein the strength distribution adjusting unit adjusts the strength distribution based on the result of measuring the melted state of the workpiece and the melted state of the filler metal. .. The additional manufacturing apparatus according to claim 1, wherein the intensity distribution adjusting unit changes the outer shape of the beam, which is the cross-sectional shape of the beam, by adjusting the intensity distribution. The additional manufacturing apparatus according to claim 1, wherein the intensity distribution adjusting unit adjusts the intensity distribution based on the temperature distribution of the workpiece. The additional manufacturing apparatus according to claim 1, wherein the intensity distribution adjusting unit adjusts the intensity distribution based on the shape of the workpiece. The additional manufacturing apparatus according to claim 1, wherein the intensity distribution adjusting unit adjusts the intensity distribution based on a shape designated by the design data. It is characterized by having a function of the strength distribution calculation unit and provided with an inference device that infers the strength distribution and processing conditions suitable for modeling the shape specified by the design data based on the design data. The additional manufacturing apparatus according to any one of claims 1 to 9. A learning device for generating a trained model for inferring the strength distribution and the processing conditions suitable for modeling the specified shape is provided.
The additional manufacturing apparatus according to claim 10, wherein the inference device infers the strength distribution and processing conditions suitable for modeling the specified shape by using the trained model. The learning device includes a data acquisition unit that acquires three-dimensional shape information indicating the designated shape, processing condition information indicating the processing conditions, and intensity distribution information indicating the intensity distribution.
The eleventh claim is characterized in that it has a model generation unit that generates the trained model using a data set including the three-dimensional shape information, the processing condition information, and the intensity distribution information. Additional manufacturing equipment. It is an addition manufacturing method that uses an addition manufacturing device to manufacture a model with the shape specified by the design data.
The process of obtaining the intensity distribution of the beam that melts the filler metal based on the design data, and
The process of generating a command indicating the obtained intensity distribution and
An addition manufacturing method comprising a step of adjusting the intensity distribution of the beam in a workpiece according to the instruction.

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