JP2023146276A - Molding device and molding device unit - Google Patents

Abstract

To enable larger-sized modeling than ever.SOLUTION: A molding robot (10) includes: a vehicle body (11) that can move adhering to a wall surface; and a molding mechanism (30) that can laminate metal. Thereby, unlike conventional robots in which a welding tool (robot arm) is moved using a transport device such as a trolley, crane, or lifter, a molding size is no longer limited by a movable range of the transport device. The robot according to the present invention, therefore, enables larger-sized molding than the conventional robots that are each moved using the transport device.SELECTED DRAWING: Figure 5

Description

The present invention relates to a modeling device and a modeling device unit.

Conventionally, a modeling method called the WAAM (Wire Arc Additive Manufacturing) method is known, which manufactures three-dimensional objects by layering molten metal using a welding manipulator (robot arm). For example, see Patent Document 1).
With this modeling method, wire-shaped weld metal is supplied from the outside, as in MIG/MAG welding, and the robot arm is moved by a transport device such as a trolley, crane, or lifter, making it possible to create relatively large-sized objects. It is.

JP2021-74981A

However, in the above-described modeling method, the size that can be modeled is limited to the movable range of the transport device. For example, when an overhead crane is used to move a robot arm, the height of the object is limited to less than the installation height of the overhead crane.
The present invention has been made in view of the above-mentioned circumstances, and an object of the present invention is to enable larger-sized modeling than conventional ones.

The modeling device according to the present invention includes:
A moving mechanism that can be moved by adhering to a wall surface,
A metal lamination mechanism capable of laminating metal;
The configuration includes:

According to the present invention, it is possible to produce larger-sized objects than in the past.

1 is a conceptual diagram showing a modeling system according to an embodiment. FIG. 1 is a perspective view of a modeling robot according to an embodiment. FIG. 3 is a diagram showing the vicinity of the tip of the torch according to the embodiment. FIG. 1 is a block diagram showing a schematic control configuration of a modeling system according to an embodiment. It is a figure for explaining modeling processing concerning an embodiment. It is a figure for explaining modeling processing concerning an embodiment.

Embodiments of the present invention will be described in detail below with reference to the drawings.

[Building system configuration]
FIG. 1 is a conceptual diagram showing a modeling system 1 according to this embodiment.
As shown in this figure, the modeling system 1 is for producing a three-dimensional metal object using a modeling robot 10. Specifically, the modeling system 1 includes a modeling robot 10, a wire feeder 5, and a control device 4.

FIG. 2 is a perspective view of the modeling robot 10.
As shown in this figure, the modeling robot 10 is a three-dimensional modeling device using the so-called WAAM method (Wire Arc Additive Manufacturing), which creates three-dimensional objects by layering molten metal.
In the following description of the configuration, the mutually orthogonal X, Y, and Z directions are set as shown in each figure. As an example, the XY plane is horizontal and the Z direction is vertical.

Specifically, the modeling robot 10 includes a vehicle body 11 and a modeling mechanism 30 mounted on the vehicle body 11.
The vehicle body 11 is an example of a moving mechanism according to the present invention, and includes a frame 12 on which the modeling mechanism 30 is mounted and four wheels 18 that support the frame 12.
Each wheel 18 (wheel main body) is formed in a spherical shape (spherical shell shape), and is rotatably supported by a rotation support portion 13 provided on the frame 12. A drive unit 16 that rotationally drives each wheel 18 is fixed to the outside of each rotation support unit 13 . The drive unit 16 is composed of, for example, a geared motor, and is connected to the wheels 18 . Then, by operating the drive unit 16, the wheels 18 can be rotated. This rotation allows the modeling robot 10 to travel on any surface.
In addition, although the number of wheels 18 arranged is four in this embodiment, it is not limited to this.

Further, each wheel 18 includes an electromagnet 19 (magnetic force generating means). The electromagnet 19 is configured to be able to change its magnetic pole direction (direction in which attractive force is generated) independently of the rotation of the wheels 18 (outer shell) for movement. Such electromagnets 19 generate magnetic force (attractive force) in a direction perpendicular to the ground contact surface of the wheels 18, thereby providing traction for running. Furthermore, the wheels 18 can be attached to a metal wall surface to move on the wall surface. Note that the magnetic force generating means built into each wheel 18 is not limited to an electromagnet as long as the magnetic pole direction can be changed, and may be, for example, a permanent magnet.

The modeling mechanism 30 is mounted on the frame 12 of the vehicle body 11. The modeling mechanism 30 is an example of a metal lamination mechanism according to the present invention, and includes a torch 34 and a displacement mechanism 35 that supports the torch 34 in a movable manner.
The torch 34 is a work tool that melts a metal wire (filler metal) W by arc discharge. The modeling robot 10 (modeling mechanism 30) uses a welding method such as MIG, MAG, or TIG to melt and stack metal wires W using a torch 34 to create a three-dimensional metal object.

The displacement mechanism 35 includes a first movement mechanism 351 , a second movement mechanism 352 , a third movement mechanism 353 , and a rotation mechanism (angle adjustment mechanism) 354 .
The first moving mechanism 351 is a mechanism that moves the torch 34 in the Y direction with respect to the vehicle body 11.

A second moving mechanism 352 is connected to the first moving mechanism 351 . The second moving mechanism 352 is a mechanism that moves the torch 34 in the X direction with respect to the vehicle body 11.
A third moving mechanism 353 is connected to the second moving mechanism 352 . The third moving mechanism 353 is a mechanism that moves the torch 34 in the vertical direction (Z direction) with respect to the vehicle body 11.

A rotating mechanism 354 is connected to the third moving mechanism 353 . The rotation mechanism 354 is connected to the torch 34 via a connecting portion 355. This rotation mechanism 354 is a mechanism for rotating the torch 34 around a horizontal axis with respect to the vehicle body 11.
With the displacement mechanism 35 having such a configuration, the position and posture of the torch 34 can be changed as appropriate.

FIG. 3 is a diagram showing the vicinity of the tip of the torch 34.
As shown in this figure, an imaging section 37 is connected and supported by the torch 34 via a connecting member 371. The imaging unit 37 is configured with, for example, a CMOS camera or a CCD camera, and images an object to be photographed including the torch 34 and the wire W, and obtains image information thereof. The acquired image information is transmitted to the control device 4. The imaging unit 37 of this embodiment photographs the melted part (the part where the wire W is melted) around the torch 34 from diagonally above in the direction in which the modeling robot 10 moves (for example, in the -Y direction).
Further, the torch 34 also supports a laser beam irradiation section 39. The laser light irradiation unit 39 irradiates the periphery of the melted portion with laser light LB. The laser beam irradiation unit 39 of this embodiment is arranged at the same position as the torch 34 in the X direction and adjacent to the torch 34 in the Y direction. Thereby, the laser beam LB from the laser beam irradiation unit 39 is irradiated with its center at the same position as the torch 34 in the X direction. Further, the laser light irradiation unit 39 of this embodiment is configured to irradiate line laser light along the X direction as the laser light LB. This allows the imaging unit 37 to accurately detect the shape of the molded metal or the like.

FIG. 4 is a block diagram showing a schematic control configuration of the modeling system 1.
As shown in this figure, the modeling robot 10 includes a communication section 101, a control section 102, and a position measuring device 110 in addition to the above configuration.
The communication unit 101 is a communication device capable of transmitting and receiving various information to and from the control device 4 . Specifically, the communication unit 101 receives signals transmitted from the control device 4 and transmits image information and the like acquired by the imaging unit 37 to the control device 4 .
The control unit 102 controls the operation of each part of the modeling robot 10 based on, for example, an operation command from the control device 4 or a predetermined operation program.

The position measuring device 110 measures the position of the modeling robot 10 itself. The specific configuration of the position measuring device 110 is not particularly limited, and may utilize, for example, GNSS (satellite positioning system). Alternatively, a sensor that measures the running direction (such as an inertial measurement device) and a running distance sensor may be used to measure the position by sequentially integrating the direction and distance traveled in a minute time, or the position may be measured at various points in the work area. The position of the modeling robot 10 is measured by detecting the placed reflector (marker) with an optical sensor and comparing it with preset reflector placement information, or the laser beam LB is photographed by the imaging unit 37. The position of the modeling robot 10 may be calculated based on the position of the metal molded object obtained by image processing the results.

The control device 4 is composed of, for example, a personal computer. The control device 4 is electrically connected to the modeling robot 10 and the wire feeder 5, and controls the operation of each part of the modeling system 1 in an integrated manner. Note that the "electrical connection" may be either a wireless connection or a wired connection.
Specifically, the control device 4 includes a CPU 41 , a storage section 42 , a communication section 43 , an input section 44 , and a display section 45 .

The CPU 41 operates each part of the control device 4 based on the operation contents of the input unit 44, develops a program stored in advance in the storage unit 42, and executes various processes in cooperation with the developed program. I do things.
The storage unit 42 is a memory configured with a RAM (Random Access Memory), a ROM (Read Only Memory), etc., and stores various programs and data, and also functions as a work area for the CPU 41. The storage unit of this embodiment stores a program for executing modeling processing, which will be described later.

The communication unit 43 is a communication device that can transmit and receive various information between the modeling robot 10 and the wire feeder 5.
The input unit 44 is an operation means through which the user performs various operations to operate the control device 4, and includes, for example, a pointing device such as a mouse and a keyboard.
The display section 45 is composed of, for example, a liquid crystal display, an organic EL display, or other display, and displays various information based on display signals from the CPU 41. The display unit 45 of this embodiment displays images captured by the imaging unit 17 and the like. Note that the display section 45 may be a touch panel that also serves as a part of the input section 44.

The wire feeder 5 is a mobile robot that supplies wire W, electric power, and gas to the modeling robot 10 while following its movement. The wire feeder 5 holds a sufficient length of wire W wound around, for example, a wire reel (not shown). In addition, the wire feeder 5 is connected to the modeling robot 10 via a cable C1 of a predetermined length (for example, about 10 m maximum), and is connected to an electric power gas supply source via a cable C2 of sufficient length (for example, several tens of meters maximum). (not shown) (see FIG. 1). The wire feeder 5 receives power and gas from the power gas supply source through the cable C2, and supplies the wire W, power, and gas to the modeling robot 10 through the cable C1.
However, the wire feeder 5 only needs to be movable independently of the modeling robot 10 and capable of supplying at least the wire W to the modeling robot 10.

Specifically, the wire feeder 5 includes a control section 51, a drive section 53, and a communication section 54.
The control unit 51 controls the operation of each part of the wire feeder 5 based on an operation command from the control device 4 or the modeling robot 10, for example.
The drive unit 53 rotates wheels 531 (see FIG. 1) to move the wire feeder 5. Note that, similarly to the wheels 18 of the modeling robot 10, the wheels 531 of the wire feeder 5 are preferably configured to be able to adhere to a wall surface and obtain traction.
The communication unit 54 is a communication device capable of transmitting and receiving various information to and from the control device 4 or the modeling robot 10.
Note that the wire feeder 5 may be configured to be able to control the supply amount of at least one of the wire W, electric power, and gas, based on a command from the control device 4 or the modeling robot 10, for example.

[Building motion]
Next, the modeling process executed when the modeling system 1 performs three-dimensional modeling will be described.
5 and 6 are diagrams for explaining this modeling process.
The modeling process is executed, for example, by the CPU 41 of the control device 4 reading out and developing a corresponding program from the storage unit 42 based on a user operation.

When the modeling process is executed, the CPU 41 of the control device 4 first sets the movement path of the modeling robot 10 and the timing of melting (lamination) of the wire W on the movement path based on the user's operation.
Here, when the user inputs shape data (for example, three-dimensional CAD data) of a desired object, the CPU 41 analyzes the shape data, sets the movement route and melting timing, and stores the data in the storage unit 42. .

Next, the CPU 41 operates the modeling robot 10 based on the set movement path and melting timing of the modeling robot 10.
The control unit 102 of the modeling robot 10 operates each unit based on the operation command transmitted from the control device 4. Thereby, the modeling robot 10 moves along the set movement path while supplying the wire W downward from the tip (lower end) of the torch 34 and melts and stacks the wire W to perform three-dimensional modeling. . The position of the modeling robot 10 is acquired by the position measuring device 110 and transmitted to the control device 4. At this time, the wire feeder 5 supplies the wire W, electric power, and gas to the modeling robot 10 while moving appropriately so as to be located within the length range of the cable C1 from the modeling robot 10.

Here, the operation of the modeling robot 10 when producing a cylindrical shaped object will be specifically explained.
As shown in FIG. 5(a), first, the modeling robot 10 melts and stacks the wires W while moving in a circular motion on the substrate S, so that the molten wires W become solidified metal. The molded article M is formed into a circular shape. If the metal molded product M is to have a thickness in the radial direction, the modeling robot 10 may move in circles with different radii.

When the height of the metal molded object M exceeds the vertical movable range of the torch 34 by repeating the stacking, the modeling robot 10 attaches the wheels 18 to the wall surface and moves the wall surface as shown in FIG. 5(b). While traveling, the upper surface of the metal molded article M is further shaped. If the height of the modeling robot 10 exceeds the length of the cable C1, as shown in FIG. 6(a), the wire feeder 5 may be moved along the wall by adhering the wheels 531 to the wall. .
Thereby, as shown in FIG. 6(b), even a large and elongated cylindrical object can be suitably formed.

Note that the shape that the modeling robot 10 can model is not limited to a cylindrical shape. If the modeling robot 10 can travel on a curved surface, it can freely create curved shapes, and even shapes that are difficult to travel within the reachable range of the torch 34 can be created.
Further, the specific operating method of the modeling robot 10 is not particularly limited, and for example, a huge object or the like may be shared among a plurality of modeling robots 10.

[Technical effects of this embodiment]
As described above, according to the present embodiment, the modeling robot 10 includes the vehicle body 11 that is movable by adhering to a wall surface, and the modeling mechanism 30 that is capable of laminating metal.
As a result, unlike the conventional method in which the welding tool (robot arm) is moved by a transport device such as a trolley, crane, or lifter, there is no longer a limitation on the molding size due to the movable range of the transport device. Therefore, it is possible to create a larger size than in the past.

Further, according to the present embodiment, the wire W and the like are supplied to the modeling robot 10 from the wire feeder 5, which is movable independently of the modeling robot 10.
Thereby, there is no need to mount the wire W on the modeling robot 10 itself, and the wire feeder 5 can be caused to follow the modeling robot 10 and supply the wire W and the like. Therefore, the cable C1 for feeding the wire W to the modeling robot 10 cannot be made infinitely long due to the friction of the wire W passing inside, etc., but by configuring the wire feeder 5 to be movable independently. , it is possible to expand the movement range of the modeling robot 10 and, by extension, the range of modeling sizes.

[others]
Although the embodiments of the present invention have been described above, the present invention is not limited to the above embodiments.
For example, in the embodiment described above, the control device 4 controls the operation of the modeling robot 10, but the method of controlling the modeling robot 10 is not particularly limited. The modeling robot 10 may operate autonomously according to a program or the like, or may be remotely controlled by an operator. In the case of remote control, it is preferable to display an image of the welding part around the torch 34 taken by the imaging section 17 of the modeling robot 10 in real time on the display section 45 to show it to the operator.

Further, in the above embodiment, the spherical wheel 18 is attracted to the ground (wall surface) by magnetic force, but the shape of the wheel 18, the type of attraction force, etc. are not particularly limited. For example, the wheel 18 may have a barrel-like shape or structure, or may be a general rubber tire, or may be adsorbed to a surface by the adhesive force of the surface of the wheel 18. The same applies to the wheels 531 of the wire feeder 5.

Further, in the above embodiment, the position of the modeling robot 10 is acquired by the position measuring device 110 mounted on the modeling robot 10 itself, but it may be acquired by a measuring device installed outside the vehicle, for example.

Further, in the above embodiment, the wire feeder 5 is supplied with electricity and gas from the power gas supply source, but for example, the wire feeder 5 is equipped with a power battery or a gas cylinder, and the modeling robot 10 is connected to the wire feeder 5 from there. may be provided with electricity and gas. Alternatively, the wire feeder 5 itself may be equipped with at least one of the wire W, a power source, and gas, and the rest may be supplied from an external source.
Further, the specific configuration of the wire feeder 5 is not particularly limited either. For example, it may be rotatable like a turntable so as not to twist the cable C1 between it and the modeling robot 10 that moves in an arc shape, or it may be rotatable like a turntable so that it can easily follow the height position of the modeling robot 10. It may also have a lifting mechanism.

Further, in the embodiment described above, the modeling mechanism 30 capable of modeling by a so-called WAAM method was described as an example of a metal lamination mechanism capable of laminating metals. However, the metal lamination mechanism according to the present invention is not limited to such a modeling mechanism, and for example, methods used in 3D printers, such as a method of curing powder or liquid resin with a laser or the like, can be suitably employed. .
Moreover, the modeling apparatus according to the present invention is not limited to one that produces a modeled object from scratch, but can also be suitably applied to, for example, one that repairs a sunken hole or the like.

In addition, the details shown in the above embodiments can be changed as appropriate without departing from the spirit of the invention.

1 Modeling system 4 Control device 5 Wire feeder (wire feeder)
10 Modeling robot (modeling device)
11 Vehicle body (moving mechanism)
12 Frame 18 Wheel 19 Electromagnet (magnetic force generating means)
30 Modeling mechanism (metal lamination mechanism)
34 Torch 41 CPU
531 Wheel C1 Cable C2 Cable M Metal molding W Wire

Claims (5)

A moving mechanism that can be moved by adhering to a wall surface,
A metal lamination mechanism capable of laminating metal;
A modeling device equipped with. The metal lamination mechanism melts metal wires with a torch and laminates them.
The modeling apparatus according to claim 1. The moving mechanism has wheels formed in a spherical shape.
The modeling apparatus according to claim 1 or claim 2. The wheel has built-in magnetic force generating means that can change the magnetic pole direction.
The modeling apparatus according to claim 3. The modeling device according to any one of claims 1 to 4,
a wire feeding device that is configured to be movable independently of the modeling device, accommodates a metal wire, and supplies the metal wire to the modeling device;
A modeling device unit comprising:

Images