JP7409836B2 - Shape inspection equipment, molding control equipment, and molding equipment - Google Patents

Description

The present disclosure relates to a shape inspection device, a shaping control device, and a shaping device.

For example, as a device for inspecting the shape of a weld bead, a shape inspection device is known that obtains the shape of a weld bead based on a shape line formed by slit light irradiated onto the weld bead. This shape inspection device obtains three-dimensional coordinates at each point of a point group of a shape line from a captured image of a shape line formed while changing its position in the scanning direction by scanning a slit light (for example, Patent Document 1 reference).

Patent No. 5758090

In the shape inspection apparatus described in Patent Document 1, it is possible to grasp the height of the surface shape with respect to a preset reference plane of the object to be inspected. However, with the shape inspection apparatus described in Patent Document 1, it is difficult to inspect the shape of the bead being formed in real time, for example, during three-dimensional layered manufacturing. Therefore, in the shape inspection device described in Patent Document 1, when a new weld bead is formed adjacent to an existing weld bead, it is difficult to inspect only the shape of the newly formed bead.

In view of the above-mentioned circumstances, at least one embodiment of the present disclosure aims to provide a shape inspection device that can inspect the shape of a bead being formed in real time during three-dimensional additive manufacturing.

(1) A shape inspection device according to at least one embodiment of the present disclosure includes:
a first shape measurement sensor that measures the first surface shape of the object before forming the bead by melting the raw material powder with an energy beam;
a second shape measurement sensor that measures a second surface shape of the shaped object after forming the bead;
an evaluation unit that evaluates the shape of the bead based on the first surface shape measured by the first shape measurement sensor and the second surface shape measured by the second shape measurement sensor;
Equipped with.

(2) The modeling control device according to at least one embodiment of the present disclosure includes:
The shape inspection device of (1) above;
When the comparing section determines that the under-thickness area exists, the modeling is configured to continue according to the modified path settings for the bead, which are modified from the initial path settings for realizing the final shape of the object. a path correction section,
Equipped with.

(3) The modeling device according to at least one embodiment of the present disclosure includes:
a shaping nozzle for melting the raw material powder with the energy beam to form the bead;
a scanning unit for scanning the modeling nozzle;
The modeling control device of (2) above;
Equipped with.

According to at least one embodiment of the present disclosure, the shape of a bead being formed can be inspected in real time during three-dimensional additive manufacturing.

FIG. 1 is a diagram schematically showing the overall configuration of a three-dimensional printing apparatus. FIG. 2 is a diagram for explaining an outline of a modeling method using an LMD method. FIG. 1 is a block diagram showing the overall configuration of a modeling control device according to some embodiments. FIG. 2 is a schematic perspective view of the vicinity of a bead that is being formed on the surface of a modeled object, viewed diagonally from above. It is a graph which shows the surface shape of a model measured by the 1st shape measurement sensor. It is a graph which shows the surface shape of a model measured by the 2nd shape measurement sensor. It is a figure which shows the cross-sectional shape of a newly installed bead calculated from the difference between a 1st surface shape and a 2nd surface shape. FIG. 3 is a schematic diagram for explaining a target shape of a bead. FIG. 3 is a schematic diagram for explaining a target shape of a bead. FIG. 3 is a schematic diagram for explaining a target shape of a bead. 6C is a diagram for explaining the target shape of each of a plurality of beads in the shaped article shown in FIG. 6C. FIG. FIG. 3 is a schematic diagram for explaining underfill areas and correction paths. FIG. 3 is a schematic diagram for explaining underfill areas and correction paths. FIG. 3 is a schematic diagram for explaining underfill areas and correction paths. FIG. 3 is a schematic diagram for explaining underfill areas and correction paths. FIG. 3 is a schematic diagram for explaining underfill areas and correction paths. It is a flow chart for explaining processing performed in a modeling control device concerning some embodiments. It is a flowchart for explaining the content of processing in an evaluation step. It is a flowchart for explaining the content of processing in an evaluation step. It is a typical diagram for explaining an example of an embodiment which does not use a 1st shape measurement sensor and a 2nd shape measurement sensor. It is a typical figure for explaining another example of an embodiment which does not use a 1st shape measurement sensor and a 2nd shape measurement sensor. It is a figure which shows the example of arrangement|positioning of a 1st shape measurement sensor and a 2nd shape measurement sensor. It is a figure which shows the example of arrangement|positioning of a 1st shape measurement sensor and a 2nd shape measurement sensor. It is a figure which shows the example of arrangement|positioning of a 1st shape measurement sensor and a 2nd shape measurement sensor. It is a figure which shows the example of arrangement|positioning of a 1st shape measurement sensor and a 2nd shape measurement sensor. It is a figure which shows the example of arrangement|positioning of a 1st shape measurement sensor and a 2nd shape measurement sensor. It is a figure which shows the example of arrangement|positioning of a 1st shape measurement sensor and a 2nd shape measurement sensor. It is a figure which shows the example of arrangement|positioning of a 1st shape measurement sensor and a 2nd shape measurement sensor.

Hereinafter, some embodiments of the present disclosure will be described with reference to the accompanying drawings. However, the dimensions, materials, shapes, relative arrangements, etc. of the components described as embodiments or shown in the drawings are not intended to limit the scope of the present disclosure, and are merely illustrative examples. do not have.
For example, expressions expressing relative or absolute positioning such as "in a certain direction,""along a certain direction,""parallel,""orthogonal,""centered,""concentric," or "coaxial" are strictly In addition to representing such an arrangement, it also represents a state in which they are relatively displaced with a tolerance or an angle or distance that allows the same function to be obtained.
For example, expressions such as "same,""equal," and "homogeneous" that indicate that things are in an equal state do not only mean that things are exactly equal, but also have tolerances or differences in the degree to which the same function can be obtained. It also represents the existing state.
For example, expressions expressing shapes such as squares and cylinders do not only refer to shapes such as squares and cylinders in a strict geometric sense, but also include uneven parts and chamfers to the extent that the same effect can be obtained. Shapes including parts, etc. shall also be expressed.
On the other hand, the expressions "comprising,""comprising,""comprising,""containing," or "having" one component are not exclusive expressions that exclude the presence of other components.

(Overall configuration of 3D printing device 1)
FIG. 1 is a diagram schematically showing the overall configuration of a three-dimensional printing apparatus to which three-dimensional printing methods according to some embodiments can be applied.
The three-dimensional printing apparatus 1 of some embodiments is an apparatus that can perform layered manufacturing using DED (Direct Energy Deposition). In additive manufacturing using DED, metal powder and metal wire can be used as materials, and the materials are melted using an arc or energy beam to form beads, and these beads are layered one after another to create three-dimensional objects. Can be formed.

The three-dimensional printing apparatus 1 of some embodiments controls a printing nozzle (nozzle device) 10 for forming a bead, a scanning section 30 for scanning the printing nozzle 10, and each part of the three-dimensional printing apparatus 1. and a modeling control device 100 for the purpose of The three-dimensional printing apparatus 1 of some embodiments includes an industrial robot 3 as a scanning unit 30. That is, the three-dimensional modeling apparatus 1 of some embodiments includes a robot arm 5 as a manipulator of the industrial robot 3, and a modeling nozzle 10 as an end effector. Note that in the three-dimensional modeling apparatus 1 of some embodiments, the scanning unit 30 is not limited to the industrial robot 3, but may also include a slide movable in each of the X-axis, Y-axis, and Z-axis directions, such as an NC device. It may include a scanning device having an axis. Moreover, the three-dimensional printing apparatus 1 of some embodiments may be a dedicated machine for layered manufacturing using the DED method.

In the following description, it is assumed that the three-dimensional modeling apparatus 1 of some embodiments is a modeling apparatus using, for example, an LMD (Laser Metal Deposition) method, as an example of the DED method. That is, the three-dimensional printing apparatus 1 of some embodiments irradiates an energy beam such as a laser beam to metal powder, which is a material of a three-dimensional layered object (three-dimensional layered object), to melt it. This is an apparatus that forms a three-dimensional layered product 20 by spraying, solidifying, and layering metal powder.
FIG. 2 is a diagram for explaining an outline of a modeling method using the LMD method. The three-dimensional modeling apparatus 1 of some embodiments includes the above-described modeling nozzle 10 and a light source 7, as shown in FIG. The modeling nozzle 10 is a modeling nozzle for supplying metal powder 13, which is a raw material for the three-dimensional layered product 20. In the following description, the three-dimensional layered object 20 is also simply referred to as the object 20 or the workpiece 20.

A light source 7 generates an energy beam 15 such as a laser beam. The energy beam 15 from the light source 7 is irradiated toward the modeling table 9 and the workpiece 20 that is being modeled. The modeling nozzle 10 supplies metal powder 13, which is a raw material for the modeled object 20, from the tip of the modeling nozzle 10. The metal powder 13 supplied from the tip of the modeling nozzle 10 scanned in the scanning direction 17 indicated by the arrow 17 is heated by the energy beam 15 and supplied in a molten state. In this way, the three-dimensional modeling apparatus 1 of some embodiments can form the linear bead 21 extending along the scanning direction of the modeling nozzle 10 on the modeling table 9 or the object 20. The three-dimensional modeling apparatus 1 of some embodiments can model the object 20 as a collection of linear beads 21 by repeating the scanning of the modeling nozzle 10.
In addition, although the light source 7 is arrange|positioned at the top of the modeling nozzle 10 shown in FIG. 2, the light source 7 may be arrange|positioned at a different location from the modeling nozzle 10.

In the following description, the front side in the direction of movement of the modeling nozzle 10 along the scanning direction 17 is referred to as the front side in the scanning direction 17, and the rear side in the direction of movement of the modeling nozzle 10 along the scanning direction 17 is referred to as the rear side in the scanning direction 17. . Further, the front side in the direction of movement of the modeling nozzle 10 along the scanning direction 17 is also called the downstream side in the scanning direction 17, and the rear side in the direction of movement of the modeling nozzle 10 along the scanning direction 17 is also called the upstream side in the scanning direction 17.

The three-dimensional printing apparatus 1 according to some embodiments includes a first shape measurement sensor 41 arranged on the front side in the scanning direction 17 with respect to the printing nozzle 10, and a first shape measurement sensor 41 arranged on the rear side in the scanning direction 17 with respect to the printing nozzle 10. A second shape measurement sensor 42 is provided.
The first shape measurement sensor 41 is a sensor for measuring the first surface shape of the object 20 before forming the bead 21, that is, the surface shape of the object 20 immediately before the bead 21 is formed by the modeling nozzle 10. It is.
The second shape measurement sensor 42 is a sensor for measuring the second surface shape of the object 20 after forming the bead 21, that is, the surface shape of the object 20 immediately after the bead 21 is formed by the modeling nozzle 10. It is.

The first shape measurement sensor 41 and the second shape measurement sensor 42 can measure the distance to the measurement object by irradiating the measurement object with the linear irradiation light 50.
The first shape measurement sensor 41 and the second shape measurement sensor 42 are configured to move together with the modeling nozzle 10. Specifically, the first shape measurement sensor 41 and the second shape measurement sensor 42 are attached to the modeling nozzle 10 or the robot arm 5, for example, via a bracket (not shown) or the like.

In the three-dimensional modeling apparatus 1 according to some embodiments, the shape of the bead 21 is determined based on the first surface shape measured by the first shape measurement sensor 41 and the second surface shape measured by the second shape measurement sensor 42. can be evaluated. This will be explained in detail below.

(Printing control device 100)
FIG. 3 is a block diagram showing the overall configuration of the modeling control device 100 according to some embodiments.
A modeling control device 100 according to some embodiments includes a shape inspection device 101, a path correction section 103, and a modeling control section 105. The shape inspection device 101 according to some embodiments includes an evaluation section 110 and a target shape calculation section 120.
The modeling control device 100 according to some embodiments includes an evaluation section 110, a target shape calculation section 120, a path correction section 103, and a modeling control section 105 as functional blocks of the modeling control device 100. Note that the evaluation section 110, the target shape calculation section 120, the path correction section 103, and the modeling control section 105 may each be configured by dedicated hardware instead of a functional block.

(Overview of evaluation unit 110)
The evaluation unit 110 according to some embodiments evaluates the shape of the bead 21 based on the first surface shape measured by the first shape measurement sensor 41 and the second surface shape measured by the second shape measurement sensor 42. It is configured as follows. Specifically, the evaluation unit 110 according to some embodiments is configured to calculate the shape of the bead 21 as described later, and compare the calculated shape of the bead 21 with a target shape of the bead 21. .

The evaluation unit 110 according to some embodiments includes a bead shape calculation unit 111 and a comparison unit 113.

Therefore, according to the modeling control device 100 according to some embodiments, the first shape measurement sensor 41 and the second shape measurement sensor are arranged on the front side and the rear side in the scanning direction 17 of the modeling nozzle 10 with respect to the modeling nozzle 10. The sensor 42 can measure the first surface shape of the object 20 before forming the bead 21 and the second surface shape of the object 20 after forming the bead 21. The shape and the second surface shape can be sequentially acquired in real time. As a result, as will be described in detail later, the shape of the newly formed bead 21 can be grasped in real time based on the difference between the first surface shape and the second surface shape, regardless of the presence or absence of the existing bead 21 or its shape. .
Furthermore, according to the modeling control device 100 according to some embodiments, the shape of the bead 21 can be evaluated by the evaluation unit 110, as will be described in detail later, so that various calculations can be performed using the evaluation results. Become.

(Overview of bead shape calculation unit 111)
The bead shape calculation unit 111 is configured to calculate the shape of the bead 21 based on the first surface shape measured by the first shape measurement sensor 41 and the second surface shape measured by the second shape measurement sensor 42. There is. The calculation of the shape of the bead 21 by the bead shape calculation unit 111 will be described in detail later.

(Overview of comparison section 113)
The comparison unit 113 compares the shape of the bead 21 calculated by the bead shape calculation unit 111 with the target shape of the bead 21, and determines an underfill area where the shape of the bead 21 does not reach the target shape of the bead 21. It is configured to determine whether or not it exists. This makes it possible to ascertain in real time whether or not there is an area with insufficient thickness during modeling.
Note that the processing content of the comparison unit 113 will be explained in detail later.

(Overview of target shape calculation unit 120)
The target shape calculation unit 120 is configured to calculate the target shape of the bead 21.
In the present disclosure, the target shape of the bead 21 refers to the shape required for each of the plurality of beads 21 constituting the modeled object 20 and the set of the plurality of beads 21 in order to obtain the final shape of the modeled object 20. Refers to the shape required in the body. Further, in the present disclosure, the underfill area refers to an area that is missing from the target shape of the bead 21.
The target shape calculation unit 120 calculates the shape required for each of the plurality of beads 21 and the shape required for the aggregate of the plurality of beads 21 based on the initial path settings described later set by the modeling control unit 105 described later. The configuration is such that the shape calculated as the target shape of the bead 21 is calculated.

Note that the target shape calculation unit 120 may calculate in advance the target shape (target cross-sectional shape) of the cross-sectional shape of the bead 21 in a cross section orthogonal to the scanning direction at each position on the scanning path of the modeling nozzle 10. The target cross-sectional shape of the bead 21 may be calculated, for example, based on the final shape of the object 20 and information on the scanning path of the modeling nozzle 10.

In addition, in this indication, the final shape of the modeled object 20 is the shape of the modeled object 20 after finishing layered modeling with the three-dimensional printing apparatus 1 which concerns on some embodiments. That is, in the present disclosure, the final shape of the modeled object 20 is the shape of the modeled object 20 at the time when the modeling process by the three-dimensional printing apparatus 1 according to some embodiments is completed, and is performed after the modeling process. This is the shape before the surface of the modeled object 20 is subjected to cutting or the like in the finishing process. In other words, in the present disclosure, the final shape of the modeled object 20 is a shape that includes a cutting allowance for finishing after modeling.
Therefore, in the present disclosure, the target shape of the bead 21 is a shape in which the above-mentioned cutting allowance is taken into consideration.

(Overview of path correction unit 103)
The path correction unit 103 is configured to make changes to the initial path settings, which will be described later, when the comparison unit 113 determines that an underfill area exists. The path settings modified by the path modification unit 103 are referred to as modified path settings. The processing contents of the path correction unit 103 will be described in detail later.

(Overview of modeling control unit 105)
The modeling control unit 105 is configured to control each part of the three-dimensional printing apparatus 1 to perform layered manufacturing based on initial path settings or modified path settings. In the present disclosure, initial path settings are path settings that are preset to realize the final shape of the object 20.
Note that the pass settings include information regarding the number of passes required for each part of the modeled object 20 in the stacking direction (height direction), the number of passes required for each layer, the scanning position of the model nozzle 10, etc. included.

For example, the modeling control unit 105 is configured to control the scanning unit 30 so that the modeling nozzle 10 is scanned at a scanning path and scanning speed based on a pass setting, that is, an initial path setting or a modified path setting.
For example, the modeling control unit 105 is configured to control the light source 7 so that the energy beam 15 having an output based on the path setting is irradiated.
For example, the modeling control unit 105 is configured to control a raw material supply device (not shown) so that the metal powder 13 is supplied at a supply amount based on the path settings.

In the printing control apparatus 100 according to some embodiments configured in this way, the printing control unit 105 controls each part of the three-dimensional printing apparatus 1 based on the path setting so as to perform layered manufacturing of the object 20. .
In the modeling control device 100 according to some embodiments, when printing the object 20, the first surface shape of the object 20 before forming the bead 21 measured by the first shape measurement sensor 41 and the second shape are measured by the first shape measurement sensor 41. The bead shape calculation unit 111 calculates the shape of the bead 21 based on the second surface shape of the object 20 after forming the bead 21 measured by the measurement sensor 42 .
In the modeling control device 100 according to some embodiments, the comparison unit 113 compares the shape of the bead 21 calculated by the bead shape calculation unit 111 with the target shape of the bead 21, and determines whether an under-thickness area exists. Determine whether or not.
In the modeling control device 100 according to some embodiments, when the comparison unit 113 determines that a lack of thickness area exists, the path correction unit 103 uses the modified path settings that have been changed from the initial path settings as a new path setting. Set as .
In the printing control device 100 according to some embodiments, the printing control unit 105 performs additive manufacturing of the object 20 by controlling each part of the three-dimensional printing device 1 based on new path settings, that is, corrected path settings. Make it continue.
In addition, in the modeling control device 100 according to some embodiments, when the comparison unit 113 determines again that there is an under-fill area when printing the object 20 based on the correction path setting, the path correction unit 103 performs the correction. Set the modified path settings with changes made to the path settings as new path settings. In the following description, setting a modified path setting as a new path setting is also expressed as setting a modified path setting.
Hereinafter, each process performed in the modeling control device 100 according to some embodiments will be described in detail.

(Calculation of the shape of the bead 21)
Hereinafter, calculation of the shape of the bead 21 in the modeling control device 100 according to some embodiments will be described.
FIG. 4 is a schematic perspective view of the vicinity of the bead 21 being formed on the surface of the modeled object 20 when viewed diagonally from above. FIG. 4 shows a state in which a new bead 21 (newly installed bead 243) is formed next to an already formed bead 21 (existing bead 241).
On the front side in the scanning direction 17 of the tip 243a of the newly installed bead 243, a first bright line 51 caused by the irradiation light 50 emitted from the first shape measurement sensor 41 appears on the surface of the shaped object 20. On the rear side in the scanning direction 17 of the tip 243a of the newly installed bead 243, a second bright line 52 caused by the irradiation light 50 emitted from the second shape measurement sensor 42 appears on the surface of the object 20.

FIG. 5A is a graph showing the surface shape of the shaped object 20 measured by the first shape measurement sensor 41. FIG. 5B is a graph showing the surface shape of the object 20 measured by the second shape measurement sensor 42. FIG. In addition, FIG. 5B shows the first shape measuring sensor 41 measuring the surface shape of the object 20 in order to obtain the graph shown in FIG. 5A. 2 is a graph showing the surface shape of the object 20 measured by the two-shape measurement sensor 42. FIG.

The first shape measurement sensor 41 measures the distance from the first shape measurement sensor 41 to the surface of the object 20 based on the first bright line 51 appearing on the surface of the object 20 .
The second shape measurement sensor 42 measures the distance from the second shape measurement sensor 42 to the surface of the object 20 based on the second bright line 52 appearing on the surface of the object 20 .

The surface shape of the object 20 measured by the first shape measurement sensor 41 is the surface shape immediately before the newly installed bead 243 is formed. The surface shape of the surface (first surface) 201 of the modeled object 20 before the new bead 243 is formed is also referred to as the first surface shape 61. Therefore, the graph shown in FIG. 5A is a graph showing the first surface shape 61.
The surface shape of the object 20 measured by the second shape measurement sensor 42 is the surface shape immediately after the newly installed bead 243 is formed. The surface shape of the surface (second surface) 202 of the modeled object 20 after the new bead 243 is formed is also referred to as a second surface shape 62. Therefore, the graph shown in FIG. 5B is a graph showing the second surface shape 62.
The first shape measurement sensor 41 and the second shape measurement sensor 42 measure the distance from a position away from the surface of the object 20 to the surface of the object 20 . Therefore, the shorter the measured distance, the higher the height of the surface of the shaped object 20.

From the separation distance Ls between the first shape measurement sensor 41 and the second shape measurement sensor 42 and the scanning speed Vs of the modeling nozzle 10, the time T1 when the same position on the surface of the object 20 is measured by the first shape measurement sensor 41 is determined. The difference from time T2 measured by the second shape measurement sensor 42 (time Δt=Ls/Vs) can be found. Therefore, by comparing the measurement result by the first shape measurement sensor 41 at a certain time T1 and the measurement result by the second shape measurement sensor 42 at time T2 after time Δt has elapsed from the time T1, The difference between the first surface shape 61 and the second surface shape 62, that is, the cross-sectional shape 65 of the newly installed bead 243 in the cross section perpendicular to the scanning direction can be calculated.

FIG. 5C is a diagram showing a cross-sectional shape 65 of the newly installed bead 243 calculated from the difference between the first surface shape 61 and the second surface shape 62. In FIG. 5C, a region corresponding to the cross-sectional shape 65 is hatched.

In the modeling control device 100 according to some embodiments, the first shape measurement sensor 41 is disposed on the front side in the scanning direction 17 with respect to the modeling nozzle 10, so that the first surface shape 61 by the first shape measurement sensor 41 is measurement becomes easy. In the modeling control device 100 according to some embodiments, the second shape measurement sensor 42 is disposed on the rear side in the scanning direction 17 with respect to the modeling nozzle 10, so that the second surface shape measured by the second shape measurement sensor 42 is 62 becomes easy to measure.

(Regarding the processing content in the bead shape calculation unit 111)
In the modeling control device 100 according to some embodiments, the bead shape calculation unit 111 calculates the first surface shape 61 measured by the first shape measurement sensor 41 and the second surface shape 62 measured by the second shape measurement sensor 42. Based on this, the cross-sectional shape 65 of the newly installed bead 243 is calculated as described above.

Next, in the modeling control device 100 according to some embodiments, the bead shape calculation unit 111 calculates the shape of the newly installed bead 243 based on the calculated cross-sectional shape 65 of the newly installed bead 243 and the information on the scanning position of the modeling nozzle 10. Calculate the three-dimensional shape. Specifically, information on the cross-sectional shape 65 of the newly installed bead 243 at the time T2, information on the three-dimensional position of the modeling nozzle 10 at the time T2, and information on the positional relationship between the modeling nozzle 10 and the second shape measurement sensor 42. Based on this, the three-dimensional position of the cross-sectional shape 65 of the newly installed bead 243 at the time T2 can be calculated. Therefore, by calculating the three-dimensional position of the cross-sectional shape 65 of the newly installed bead 243 at an arbitrary time T, the bead shape calculation unit 111 calculates the three-dimensional position of the cross-section of the newly installed bead 243 formed within a certain period. Calculate. Note that the three-dimensional position of the cross section of the newly installed bead 243 obtained in this way is obtained as point group data.
Therefore, the bead shape calculation unit 111 calculates information on the three-dimensional shape of the newly installed bead 243 from the point cloud data obtained in this way. In the following description, information on a three-dimensional shape is also simply expressed as a three-dimensional shape, and calculating information on a three-dimensional shape is also simply expressed as calculating a three-dimensional shape.
The bead shape calculation unit 111 also calculates information on the three-dimensional shape of an aggregate of a plurality of beads 21 including the newly installed bead 243 and the existing bead 241, and information on the three-dimensional shape of other newly installed beads 243 that have already been calculated. Calculated based on.

In this way, in the modeling control device 100 according to some embodiments, the bead shape calculation unit 111 calculates the first surface shape 61 measured by the first shape measurement sensor 41 and the second surface shape measured by the second shape measurement sensor 42. 2. The three-dimensional shape of the bead 21 is calculated based on the surface shape 62 and information on the scanning position of the modeling nozzle 10.
According to the modeling control device 100 according to some embodiments, the three-dimensional shape of the bead 21 can be grasped in real time.

In addition, in the modeling control device 100 according to some embodiments, the bead shape calculation unit 111 calculates the first surface shape 61 measured by the first shape measurement sensor 41 and the second surface shape measured by the second shape measurement sensor 42. A cross-sectional shape 65 that is the difference from the shape 62 is calculated. Then, the bead shape calculation unit 111 calculates the three-dimensional shape of the bead 21 based on the cross-sectional shape 65 and the information on the scanning position of the modeling nozzle 10. That is, according to the modeling control device 100 according to some embodiments, the bead shape calculation unit 111 calculates the cross-section of the newly installed bead 243 based on the cross-sectional shape 65 and the information on the scanning position of the modeling nozzle 10, as described above. Three-dimensional positions can be calculated as point cloud data. According to the modeling control device 100 according to some embodiments, the bead shape calculation unit 111 can calculate information on the three-dimensional shape of the newly installed bead 243 from the point cloud data.

In addition, in the modeling control device 100 according to some embodiments, the bead shape calculation unit 111 may calculate the three-dimensional shape of the newly installed bead 243 as follows.
For example, the bead shape calculation unit 111 calculates the three-dimensional position of the first surface shape 61 based on the first surface shape 61 measured by the first shape measurement sensor 41 and information on the scanning position of the modeling nozzle 10. It may be calculated as one point group data. Furthermore, the bead shape calculation unit 111 calculates the three-dimensional position of the second surface shape 62 based on the second surface shape 62 measured by the second shape measurement sensor 42 and the information on the scanning position of the modeling nozzle 10. It may also be calculated as two-point group data. Then, the bead shape calculation unit 111 calculates the newly installed bead 243 based on the first point group data and the second point group data, specifically, from the difference between the first point group data and the second point group data. The cross-sectional shape 65 may be calculated as point cloud data. Furthermore, the bead shape calculation unit 111 may calculate the three-dimensional shape of the newly installed bead 243 from the point cloud data.

Furthermore, in the modeling control device 100 according to some embodiments, the bead shape calculation unit 111 may calculate the three-dimensional shape of the newly installed bead 243 as follows.
For example, the bead shape calculation unit 111 calculates the three-dimensional position of the first surface shape 61 based on the first surface shape 61 measured by the first shape measurement sensor 41 and information on the scanning position of the modeling nozzle 10. It may be calculated as one point group data. Then, the bead shape calculation unit 111 may calculate information on the three-dimensional shape of the first surface shape 61 from the first point group data.
Furthermore, the bead shape calculation unit 111 calculates the three-dimensional position of the second surface shape 62 based on the second surface shape 62 measured by the second shape measurement sensor 42 and the information on the scanning position of the modeling nozzle 10. It may also be calculated as two-point group data. Then, the bead shape calculation unit 111 may calculate information on the three-dimensional shape of the second surface shape 62 from the second point group data.
Furthermore, the bead shape calculation unit 111 may calculate the three-dimensional shape of the newly installed bead 243 from the difference between the three-dimensional shape information of the first surface shape 61 and the three-dimensional shape information of the second surface shape 62.

(Regarding the processing content in the comparison unit 113)
As described above, in the modeling control device 100 according to some embodiments, the comparison unit 113 compares the shape of the bead 21 calculated by the bead shape calculation unit 111 and the target shape of the bead 21. Then, the comparison unit 113 determines whether there is an under-thickness area where the shape of the bead 21 does not reach the target shape of the bead 21.

(When comparing the three-dimensional shape of the bead 21 and the target shape)
The comparison unit 113 acquires information on the three-dimensional shape of the newly installed bead 243 from the bead shape calculation unit 111. The comparison unit 113 acquires target shape information for the newly installed bead 243 from the target shape calculation unit 120. Then, the comparison unit 113 compares the three-dimensional shape of the newly installed bead 243 and the target shape of the newly installed bead 243 based on the acquired information.
Further, the comparison unit 113 acquires information on the three-dimensional shape of the aggregate of the plurality of beads 21 including the new bead 243 and the existing bead 241 from the bead shape calculation unit 111. The comparison unit 113 acquires information on the target shape for the aggregate from the bead shape calculation unit 111. Then, the comparison unit 113 compares the three-dimensional shape of the aggregate of the plurality of beads 21 including the newly installed bead 243 and the existing bead 241 with the target shape of the aggregate based on the acquired information.

If there is a region where the three-dimensional shape of the newly installed bead 243 does not reach the target shape for the newly installed bead 243, the comparison unit 113 calculates the position and range of the region, that is, the shape of the region, Determine that the area exists.
If there is a region in which the three-dimensional shape of the aggregate of a plurality of beads 21 including the newly installed bead 243 and the existing bead 241 does not reach the target shape for the aggregate, the comparison unit 113 calculates the shape of the area. At the same time, it is determined that there is a region with insufficient thickness.

(When comparing the cross-sectional shape of the bead 21 and the target cross-sectional shape)
The comparison unit 113 may determine whether or not a lack-of-thickness region exists by comparing the cross-sectional shape of the bead 21 with a target shape (target cross-sectional shape).
For example, the comparison unit 113 acquires information on the cross-sectional shape 65 of the newly installed bead 243 from the bead shape calculation unit 111. Furthermore, the comparison unit 113 acquires information on the target cross-sectional shape corresponding to the current scanning position of the modeling nozzle 10 from the target shape calculation unit 120. Then, the comparison unit 113 compares the cross-sectional shape 65 of the newly installed bead 243 and the target cross-sectional shape based on the acquired information.

If there is a region in which the cross-sectional shape 65 of the newly installed bead 243 does not reach the target cross-sectional shape, the comparison unit 113 calculates the range of the region and determines that there is an under-thickness region. Note that the underfill area will be explained together with the processing contents of the path correction unit 103, which will be described later.

Thus, in some embodiments, as described above, the bead shape calculation unit 111 calculates the first surface shape 61 measured by the first shape measurement sensor 41 and the second surface shape measured by the second shape measurement sensor 42. A cross-sectional shape 65 of the bead 21 in a cross section perpendicular to the scanning direction 17 of the modeling nozzle 10 is calculated from the difference with the surface shape 62. In some embodiments, as described above, the comparison unit 113 can determine whether or not an under-thickness region exists by comparing the cross-sectional shape 65 of the bead 21 and the target cross-sectional shape.
Therefore, according to some embodiments, it is not necessary to calculate the three-dimensional shape of the bead 21, so the calculation load on the bead shape calculation unit 111 can be reduced, and the response speed of shape calculation can be improved.

(Regarding the processing content in the target shape calculation unit 120)
As described above, in the modeling control device 100 according to some embodiments, the target shape calculation unit 120 calculates the target shape of the bead 21.
6A, FIG. 6B, and FIG. 6C are schematic diagrams for explaining the target shape of the bead 21. FIG. 6A shows an example in which beads 21 are sequentially stacked vertically upward. FIG. 6B is an example of a case where beads 21 are sequentially stacked in a direction oblique to the vertical direction, and there is an overhang portion in which the beads 21 have a surface facing downward. FIG. 6C is an example of a shaped object 20 formed by stacking a plurality of layers 219 in the height direction, each of which is formed by a plurality of beads 21 located at the same height, for example.

In the modeled object 20, when it is necessary to adjust the surface condition or ensure dimensional accuracy, a cutting allowance is required for performing finishing processing after modeling. That is, as shown in FIGS. 6A, 6B, and 6C, the final shape 211 of the object 20 has a cutting allowance 215 added to the shape 213 of the object 20 after finishing, which is defined as the dimensions of the CAD data of the object 20. It is necessary to have a size equal to or larger than the shape 217 in which .

Therefore, in the modeling control device 100 according to some embodiments, the target shape calculation unit 120 calculates the target shape of the bead 21 from the shape 217 obtained by adding the cutting allowance 215 to the shape 213 of the molded object 20 after finishing processing. do.
For example, regarding the target shape of the aggregate 220 of a plurality of beads 21, the target shape calculation unit 120 calculates the dimension value by adding the dimension of the cutting allowance 215 to the dimension in the CAD data of the object 20, and The dimension values are set as the target shape for the aggregate 220 of the plurality of beads 21.

For example, regarding the target shape for each of the plurality of beads 21, the target shape calculation unit 120 calculates a dimension value by adding the dimension of the cutting allowance 215 to the dimension in the CAD data of the object 20, and calculates the dimension value and the number of beads 21 arranged.

FIG. 7 is a diagram for explaining the target shape of each of the plurality of beads 21 in the shaped object 20 shown in FIG. 6C.
As shown in FIG. 7, the width W1 of the bead 21 required for the bead 231 that participates in forming the cutting allowance 215, and the width W2 of the bead 21 required for the bead 233 that does not participate in the formation of the cutting allowance 215. may be different.

As described above, by obtaining the target shape of the bead 21 and the target shape of the aggregate 220 based on the CAD data of the object 20, it is easy to obtain the target shape of the bead 21 and the target shape of the aggregate 220. Become.

As described above, by obtaining the target shape of the bead 21 and the target shape of the aggregate 220 based on the CAD data of the object 20 and the cutting allowance 215 of the object 20 after modeling, the cutting allowance 215 can be included. The target shape of the beads 21 and the target shape of the aggregate 220 can be obtained.
The modeling control device 100 according to some embodiments includes the target shape calculation unit 120, so that even if data regarding the target shape of the bead 21 or the target shape of the aggregate 220 is not provided from the outside, the modeled object 20 Data regarding the target shape of the bead 21 and the target shape of the aggregate 220 can be obtained based on the CAD data.

(Regarding the processing content and underfill area in the path correction unit 103)
As described above, in the modeling control device 100 according to some embodiments, when the comparison unit 113 determines that a missing area exists, the path correction unit 103 adds a pass to fill the missing area. Set a modified path setting with changes made to the path setting. Hereinafter, changing the path settings will be explained while giving examples of various underfill areas.

FIG. 8A is a schematic diagram for explaining an example of a lack of thickness area that may appear when beads 21 are sequentially stacked vertically upward as shown in FIG. 6A, and a correction path.
In the example shown in FIG. 8A, although an aggregate 220 of beads 21 is modeled according to the initial path setting, the height of the aggregate 220 of beads 21 has not reached the height of the target shape 250 (shape 217) of the aggregate 220. The aggregate 220 in this case is shown by a solid line.
In the example shown in FIG. 8A, the region above the upper surface of the aggregate 220 and surrounded by the two-dot chain line indicating the target shape 250 (shape 217) is the underfill region 300.

In such a case, the path correction unit 103 calculates the number of additional passes required to reach the height of the target shape 250 (shape 217) of the aggregate 220. Then, the path correction unit 103 sets the correction path settings so as to add paths by the calculated number of additional paths.

The modeling control unit 105 controls the scanning unit 30 so that the modeling nozzle 10 is scanned at the scanning path and scanning speed based on the newly set correction path settings. As a result, a new bead 25 is formed based on the corrected path setting, as shown by the broken line in FIG. 8A. As a result, the height of the aggregate 220 reaches the height of the target shape 250 (shape 217) of the aggregate 220.

FIG. 8B is a schematic diagram for explaining another example of the under-thickness region that may appear when the beads 21 are sequentially stacked vertically upward as shown in FIG. 6A, and a correction path. be.
In the example shown in FIG. 8B, while the bead 21 is being formed according to the initial pass setting, the size of the bead 21 in the width direction, that is, the size in the left and right direction in FIG. This shows an example of a case where the size has not been reached.
In the example shown in FIG. 8B, the region surrounded by the two-dot chain line indicating the target shape 260 of the bead 21 excluding the region occupied by the already formed bead 21 is the underfill region 300.

In such a case, the path correction unit 103 performs a process to form a new adjacent bead 26 adjacent to the already formed bead 21 in the width direction so as to fill the missing area 300 shown in FIG. 8B. Include additional paths in the fix path settings.
Further, the path modification unit 103 changes the setting regarding the width of the bead 21 in the initial path setting so as to form a new wide bead 27 above the already formed bead 21.

The modeling control unit 105 controls the scanning unit 30 based on the newly set correction path settings. As a result, new adjacent beads 26 and wide beads 27 are formed based on the corrected path settings, as shown by broken lines in FIG. 8B. As a result, the shape of the aggregate 220 satisfies the target shape 250 (shape 217) of the aggregate 220.

FIG. 8C is a schematic diagram for explaining still another example of a lack of thickness area that may appear when beads 21 are sequentially stacked vertically upward as shown in FIG. 6A, and a correction path. It is.
In the example shown in FIG. 8C, although the aggregate 220 of beads 21 is modeled according to the initial path setting, the shape of the aggregate 220 of beads 21 is aligned with the target shape 250 (shape 217) of the aggregate 220 above the aggregate 220. An example is shown in which an unreached area occurs.
In the example shown in FIG. 8C, the region above the upper surface of the aggregate 220 and surrounded by the two-dot chain line indicating the target shape 250 (shape 217) is the underfill region 300. In the example shown in FIG. 8C, the underfill area 300 is hatched with a thin solid line.

In such a case, the path correction unit 103 includes an additional pass for forming a new bead 25 in the correction path settings so as to fill the missing area 300 shown in FIG. 8C.

The modeling control unit 105 controls the scanning unit 30 so that the modeling nozzle 10 is scanned at the scanning path and scanning speed based on the newly set correction path settings. As a result, a new bead 25 is formed based on the corrected path setting, as shown by the broken line in FIG. 8C. As a result, the shape of the aggregate 220 satisfies the target shape 250 (shape 217) of the aggregate 220.

FIG. 8D is a schematic diagram for explaining an example of a lack of thickness area that may appear when beads 21 are sequentially stacked in a direction inclined to the vertical direction as shown in FIG. 6B, and a correction path. This is a diagram.
In the example shown in FIG. 8D, although an aggregate 220 of beads 21 is modeled according to the initial path setting, the stacking of the beads 21 is poor due to the influence of overhang, and the overhang angle of the aggregate 220 is lower than the target of the aggregate 220. An example of a case where the overhang angle deviates from the shape 250 (shape 217) is shown by a solid line.
In the example shown in FIG. 8D, the region surrounded by the two-dot chain line indicating the target shape 250 of the aggregate 220, excluding the region occupied by the already formed beads 21, is the underfill region 300.

In such a case, the path correction unit 103 adds a new bead 25 to fill the missing area 300 located below the upper surface of the aggregate 220 among the missing areas 300 shown in FIG. 8D. Include additional paths to form in modified path settings.
Further, the path modification unit 103 changes the setting regarding the width of the bead 21 in the initial path setting so as to form a new wide bead 27 above the already formed bead 21.

The modeling control unit 105 controls the scanning unit 30 based on the newly set correction path settings. As a result, a new bead 25 and wide bead 27 are formed based on the corrected path settings, as shown by the broken line in FIG. 8D. As a result, the shape of the aggregate 220 satisfies the target shape 250 (shape 217) of the aggregate 220.

FIG. 8E shows another example of the under-thickness region that may appear when beads 21 are sequentially stacked in a direction inclined to the vertical direction as shown in FIG. 6B, and a correction path. It is a schematic diagram.
In the example shown in FIG. 8E, although the aggregate 220 of beads 21 is modeled according to the initial pass settings, the size of each bead 21 in the width direction, that is, the size in the left-right direction in FIG. This represents an example of a case where the magnitude in the direction has not been reached.
In the example shown in FIG. 8E, the region surrounded by the two-dot chain line indicating the target shape 250 of the aggregate 220, excluding the region occupied by the already formed beads 21, is the underfill region 300. In the example shown in FIG. 8E, the underfill area 300 is hatched with a thin solid line.

In such a case, the path correction unit 103 includes an additional pass for forming a new bead 25 in the correction path settings so as to fill the missing area 300 shown in FIG. 8E.

The modeling control unit 105 controls the scanning unit 30 based on the newly set correction path settings. As a result, a new bead 25 is formed based on the corrected path setting, as shown by the broken line in FIG. 8E. As a result, the shape of the aggregate 220 satisfies the target shape 250 (shape 217) of the aggregate 220.

As described above, according to some embodiments, when the comparison unit 113 determines that the missing area 300 exists, the path correction unit 103 adjusts the correction path so as to add a path to fill the missing area 300. Configure settings. Thereby, even if the missing area 300 exists, the missing area 300 can be filled with the additional pass.

(flowchart)
FIG. 9 is a flowchart for explaining processing performed in the modeling control device 100 according to some embodiments. When modeling is started in the three-dimensional printing apparatus 1, an arithmetic unit (not shown) of the printing control apparatus 100 according to some embodiments stores a program for executing the process of the flowchart shown in FIG. 9 from a storage unit (not shown). Load. Then, the arithmetic device starts processing based on the read program.
Note that in the following description, calculation of the shape of the bead 21 according to the present disclosure and each process based on the calculated shape of the bead 21 will be mainly explained, and description of other processes will be omitted.

In the first surface shape measurement step S1, the bead shape calculation unit 111 of the modeling control device 100 causes the first shape measurement sensor 41 to measure the first surface shape 61.
Next, in the second surface shape measurement step S3, the bead shape calculation unit 111 of the modeling control device 100 causes the second shape measurement sensor 42 to measure the second surface shape 62.

In the evaluation step S5, the evaluation unit 110 in the modeling control device 100 calculates the shape of the bead 21 in the bead shape calculation unit 111, and compares the shape of the bead 21 calculated by the bead shape calculation unit 111 and the target of the bead 21 in the comparison unit 113. Compare with the shape. Then, in the evaluation step S5, the evaluation section 110 in the modeling control device 100 determines in the comparison section 113 whether or not there is an under-fill area.
Details of the evaluation step S5 will be explained later.

In the evaluation step S5, if it is determined that the underfill area exists, an affirmative determination is made in step S11, and the process proceeds to the correction path setting step S7.
In the correction path setting step S7, the path correction unit 103 of the modeling control device 100 sets correction path settings, for example, as described in FIGS. 8A to 8E, and returns to the first surface shape measurement step S1.

If it is determined in the evaluation step S5 that there is no underfill area, a negative determination is made in step S11 and the process proceeds to step S13.
In step S13, the modeling control device 100 determines whether modeling is completed. If the modeling is not completed, a negative determination is made in step S13 and the process returns to the first surface shape measurement step S1.
If the modeling has been completed, an affirmative determination is made in step S13, and the modeling control device 100 ends the processing of this program.

(Details of evaluation process S5)
FIG. 10 is a flowchart for explaining the contents of the processing in the evaluation step S5. Note that FIG. 10 is a flowchart for explaining the process for comparing the three-dimensional shape of the bead 21 and the target shape.

In the bead shape calculation step S51, the bead shape calculation unit 111 of the modeling control device 100 calculates the first surface shape 61 measured by the first shape measurement sensor 41 and the second surface shape 62 measured by the second shape measurement sensor 42. Based on this, the cross-sectional shape 65 of the newly installed bead 243 is calculated as described above. Then, the bead shape calculation unit 111 calculates the three-dimensional shape of the newly installed bead 243 as described above based on the calculated cross-sectional shape 65 of the newly installed bead 243 and the information on the scanning position of the modeling nozzle 10. Furthermore, the bead shape calculation unit 111 calculates information on the three-dimensional shape of the aggregate 220 of the plurality of beads 21 as described above.

In the target shape calculation step S53, the target shape calculation unit 120 of the modeling control device 100 calculates the target shape 250 for the aggregate 220 of the plurality of beads 21 and the target shape 260 of the beads 21 as described above.

In the comparison step S55, the comparison unit 113 of the modeling control device 100 compares the three-dimensional shape of the newly installed bead 243 calculated in the bead shape calculation step S51 with the target shape 260 for the newly installed bead 243 calculated in the target shape calculation step S53. Compare. In the comparison step S55, the comparison unit 113 of the modeling control device 100 compares the three-dimensional shape of the aggregate 220 of the plurality of beads 21 calculated in the bead shape calculation step S51 with the aggregate 220 calculated in the target shape calculation step S53. A comparison is made with the target shape 250 for .
Then, in the comparison step S55, the comparison unit 113 of the modeling control device 100 determines the presence or absence of the under-thickness area 300 from the result of the above comparison, and if the under-thickness area 300 exists, the shape of the under-thickness area 300. Calculate.

After the comparison step S55 is performed, the process returns to step S11 in FIG.

FIG. 11 is a flowchart for explaining the contents of the processing in the evaluation step S5. Note that FIG. 11 is a flowchart for explaining the process for comparing the cross-sectional shape of the bead 21 and the target cross-sectional shape.

In the bead shape calculation step S51A, the bead shape calculation unit 111 of the modeling control device 100 calculates the first surface shape 61 measured by the first shape measurement sensor 41 and the second surface shape 62 measured by the second shape measurement sensor 42. Based on this, the cross-sectional shape 65 of the newly installed bead 243 is calculated as described above.

In the target shape calculation step S53A, the target shape calculation unit 120 of the modeling control device 100 calculates the target cross-sectional shape of the bead 21 as described above.

In the comparison step S55A, the comparison unit 113 of the modeling control device 100 compares the cross-sectional shape 65 of the newly installed bead 243 calculated in the bead shape calculation step S51 with the target cross-sectional shape of the newly installed bead 243 calculated in the target shape calculation step S53. Compare.
Then, in the comparison step S55A, the comparison unit 113 of the modeling control device 100 determines the presence or absence of the under-thickness area 300 from the result of the above comparison, and if the under-thickness area 300 exists, the shape of the under-thickness area 300. Calculate.

After the comparison step S55A is performed, the process returns to step S11 in FIG.

(About an embodiment that does not use the first shape measurement sensor 41 and the second shape measurement sensor 42)
(When using the imaging device 45)
FIG. 12 is a schematic diagram for explaining an example of an embodiment that does not use the first shape measurement sensor 41 and the second shape measurement sensor 42, and shows the vicinity of the modeling nozzle 10.
In the embodiment shown in FIG. 12 , the modeling control device 100 includes one imaging device 45 instead of the first shape measurement sensor 41 and the second shape measurement sensor 42 .
In the embodiment shown in FIG. 12, the imaging device 45 is preferably configured to be able to image at least the vicinity of the tip of the newly installed bead 243, and may be configured to be able to image the entire shaped object 20.

In the embodiment shown in FIG. 12, information regarding the second surface shape 62 of the object 20 after forming the bead 21 is acquired from image data obtained by photographing the surface of the object 20 with the imaging device 45. . Note that by photographing the surface of the object 20 with the imaging device 45 before the new bead 243 is formed, the first surface shape 61 of the object 20 before the bead 21 is formed is determined based on the obtained image data. You can obtain information about
Therefore, in the embodiment shown in FIG. 12, the modeling control device 100 can calculate the shape of the bead 21 in the bead shape calculation unit 111, similarly to the several embodiments described above.
Note that the imaging device 45 may be configured to move together with the modeling nozzle 10, may be configured to be movable independently of the modeling nozzle 10, or may be immobile.

Note that when the number of imaging devices 45 is one, even if the imaging device 45 is within the area that can be imaged, depending on the shape of the object 20, for example, the object 20 itself may interfere with the image of the object 20. There is a possibility that there will be areas on the surface that cannot be photographed. In such a case, by installing the plurality of imaging devices 45 at different positions, it is possible to suppress the occurrence of areas that cannot be photographed.

(When using the three-dimensional shape measuring device 47)
FIG. 13 is a schematic diagram for explaining another example of the embodiment in which the first shape measurement sensor 41 and the second shape measurement sensor 42 are not used, and shows the vicinity of the modeling nozzle 10.
In the embodiment shown in FIG. 13, the modeling control device 100 includes one three-dimensional shape measuring device 47 instead of the first shape measuring sensor 41 and the second shape measuring sensor 42.
In the embodiment shown in FIG. 13, the three-dimensional shape measuring device 47 is preferably configured to be able to measure at least the shape near the tip of the newly installed bead 243, and is configured to be able to measure the entire object 20. You can leave it there.

In the embodiment shown in FIG. 13, the second surface shape 62 of the object 20 after forming the bead 21 is determined from measurement data obtained by measuring the surface shape of the object 20 with the three-dimensional shape measuring instrument 47. Get information. Note that by measuring the surface shape of the object 20 with the three-dimensional shape measuring device 47 before the new bead 243 is formed, the shape of the object 20 before the bead 21 is formed is measured based on the obtained measurement data. Information regarding the first surface shape 61 can be acquired.
Therefore, in the embodiment shown in FIG. 13, the modeling control device 100 can calculate the shape of the bead 21 in the bead shape calculation unit 111, similarly to the several embodiments described above.
Note that the three-dimensional shape measuring device 47 may be configured to move together with the modeling nozzle 10, may be configured to be movable independently of the modeling nozzle 10, or may be immobile.

Note that when the number of three-dimensional shape measuring devices 47 is one, even within the measurable area by the three-dimensional shape measuring device 47, depending on the shape of the object 20, for example, the object 20 itself may get in the way. Therefore, there is a possibility that an area that cannot be measured may occur on the surface of the modeled object 20. In such a case, by installing a plurality of three-dimensional shape measuring devices 47 at different positions, it is possible to suppress the occurrence of areas that cannot be measured.

The present disclosure is not limited to the embodiments described above, and also includes forms in which modifications are added to the embodiments described above, and forms in which these forms are appropriately combined.
For example, in some of the embodiments described above, the target shape of the bead 21 may be acquired from outside the modeling control device 100. In this case, the target shape calculation unit 120 is not necessarily an essential configuration.

For example, in some embodiments described above, the first shape measurement sensor 41 is arranged in front of the modeling nozzle 10 in the scanning direction 17, and the second shape measurement sensor 42 is arranged in the scanning direction 17 with respect to the modeling nozzle 10. It is located at the rear. However, as long as the first surface shape 61 and the second surface shape 62 can be measured, the placement positions of the first shape measurement sensor 41 and the second shape measurement sensor 42 are not limited to the embodiments described above.
14A to 14G are diagrams showing modified examples of the arrangement positions of the first shape measurement sensor 41 and the second shape measurement sensor 42. FIG. Note that FIGS. 14A to 14G are views of the modeling nozzle 10, the first shape measurement sensor 41, and the second shape measurement sensor 42 as viewed from above the modeling nozzle 10.

For example, as shown in FIGS. 14A to 14C, the first shape measurement sensor 41 and the second shape measurement sensor 42 may be arranged at the same position as the modeling nozzle 10 in the scanning direction 17. That is, as shown in FIGS. 14A to 14C, the modeling nozzle 10, the first shape measurement sensor 41, and the second shape measurement sensor 42 may be arranged side by side along the width direction of the bead 21 forming them. In the following description, the width direction of the bead 21 to be formed is a direction perpendicular to the scanning direction 17, and is also referred to as a direction perpendicular to the scanning direction 17.

In this case, for example, as shown in FIGS. 14A and 14B, the first shape measurement sensor 41 and the second shape measurement sensor 42 may be arranged on one side in the direction perpendicular to the scanning direction 17. Note that, for example, as shown in FIG. 14A, the first shape measurement sensor 41 and the second shape measurement sensor 42 may be arranged side by side along the scanning direction 17, and as shown in FIG. 14B, the first shape measurement sensor 41 and the second shape measurement sensor 42 may be arranged side by side in a direction orthogonal to the scanning direction 17. Further, as shown in FIG. 14C, the first shape measurement sensor 41 and the second shape measurement sensor 42 may be arranged on opposite sides of the modeling nozzle 10.

For example, as shown in FIGS. 14D and 14E, the first shape measurement sensor 41 and the second shape measurement sensor 42 may be arranged in front of the modeling nozzle 10 in the scanning direction 17. Note that, for example, as shown in FIG. 14D, the first shape measurement sensor 41 and the second shape measurement sensor 42 may be arranged side by side in the direction orthogonal to the scanning direction 17, and as shown in FIG. The sensor 41 and the second shape measurement sensor 42 may be arranged side by side along the scanning direction 17.

For example, as shown in FIGS. 14F and 14G, the first shape measurement sensor 41 and the second shape measurement sensor 42 may be arranged on the rear side in the scanning direction 17 with respect to the modeling nozzle 10. Note that, for example, as shown in FIG. 14F, the first shape measurement sensor 41 and the second shape measurement sensor 42 may be arranged side by side in a direction orthogonal to the scanning direction 17, and as shown in FIG. The sensor 41 and the second shape measurement sensor 42 may be arranged side by side along the scanning direction 17.
Note that in FIGS. 14A to 14G, the first shape measurement sensor 41 and the second shape measurement sensor 42 are arranged in the scanning direction 17 or in a direction orthogonal to the scanning direction 17; They may be arranged in a direction different from the orthogonal direction.

The contents described in each of the above embodiments can be understood as follows, for example.
(1) The shape inspection device 101 according to at least one embodiment of the present disclosure checks the first surface shape 61 of the shaped object 20 before melting the raw material powder (metal powder 13) with the energy beam 15 to form the bead 21. A first shape measurement sensor 41 for measurement is provided. The shape inspection device 101 according to at least one embodiment of the present disclosure includes a second shape measurement sensor 42 that measures the second surface shape 62 of the object 20 after forming the bead 21 . The shape inspection device 101 according to at least one embodiment of the present disclosure detects the bead 21 based on the first surface shape 61 measured by the first shape measurement sensor 41 and the second surface shape 62 measured by the second shape measurement sensor 42. The evaluation unit 110 is provided to evaluate the shape of the image.

According to the configuration (1) above, the first surface shape 61 of the object 20 before the bead 21 is formed by the first shape measurement sensor 41 and the second shape measurement sensor 42 and the object after the bead 21 is formed. Since the 20 second surface shapes 62 can be measured, the first surface shapes 61 and the second surface shapes 62 can be sequentially acquired in real time by scanning the modeling nozzle 10. Thereby, the shape of the newly formed bead (newly installed bead 243) can be grasped in real time based on the difference between the first surface shape 61 and the second surface shape 62, regardless of the presence or absence and shape of the existing bead 241.
Further, according to the configuration (1) above, the shape of the bead 21 can be evaluated by the evaluation section 110, so that various calculations can be performed using the evaluation results.

(2) In some embodiments, in the configuration of (1) above, the evaluation unit 110 includes a first surface shape 61 measured by the first shape measurement sensor 41 and a second surface measured by the second shape measurement sensor 42. The bead shape calculating section 111 calculates the shape of the bead 21 based on the shape 62. The evaluation unit 110 compares the shape of the bead 21 calculated by the bead shape calculation unit 111 with the target shape of the bead 21, and determines that there is an underfill area 300 where the shape of the bead 21 does not reach the target shape of the bead 21. It includes a comparison unit 113 that determines whether or not.

According to the configuration (2) above, it is possible to ascertain the presence or absence of the underfill area 300 in real time during modeling.

(3) In some embodiments, in the configuration of (2) above, the target shape 260 of the bead 21 is obtained based on CAD data of the object 20.

According to the configuration (3) above, it is easy to obtain the target shape 260 of the bead 21.

(4) In some embodiments, in the configuration (3) above, the target shape 260 of the bead 21 is obtained based on the CAD data of the modeled object 20 and the cutting allowance 215 of the modeled object 20 after modeling. .

According to the configuration (4) above, the target shape 260 of the bead 21 including the cutting allowance 215 of the modeled object 20 after modeling can be obtained.

(5) In some embodiments, the configuration of (3) or (4) above further includes a target shape calculation unit 120 that calculates the target shape 260 of the bead 21.

According to configuration (5) above, data on the target shape 260 of the bead 21 can be obtained based on the CAD data of the object 20 even if the data on the target shape 260 of the bead 21 is not provided from the outside.

(6) In some embodiments, in any of the configurations (2) to (5) above, the bead shape calculation unit 111 calculates the first surface shape 61 measured by the first shape measurement sensor 41 and the second surface shape measured by the first shape measurement sensor 41. The three-dimensional shape of the bead 21 is calculated based on the second surface shape 62 measured by the shape measurement sensor 42 and information on the scanning position of the modeling nozzle 10.

According to the configuration (6) above, the three-dimensional shape of the bead 21 can be grasped in real time.

(7) In some embodiments, in the configuration of (6) above, the bead shape calculation unit 111 calculates the first surface shape 61 measured by the first shape measurement sensor 41 and the first surface shape 61 measured by the second shape measurement sensor 42. A cross-sectional shape 65 that is a difference from the second surface shape 62 is calculated, and a three-dimensional shape of the bead 21 is calculated based on the cross-sectional shape 65 and information on the scanning position.

According to the configuration (7) above, the three-dimensional shape of the bead 21 can be calculated as described above.

(8) In some embodiments, in any of the configurations (2) to (5) above, the bead shape calculation unit 111 calculates the first surface shape 61 measured by the first shape measurement sensor 41 and the second surface shape A cross-sectional shape 65 of the bead 21 in a cross section perpendicular to the scanning direction 17 of the modeling nozzle 10 is calculated from the difference from the second surface shape 62 measured by the shape measurement sensor 42.

According to the configuration (8) above, since it is not necessary to calculate the three-dimensional shape of the bead 21, the calculation load on the bead shape calculation section 111 can be reduced, and the response speed of shape calculation can be improved.

(9) In some embodiments, in any of the configurations (1) to (8) above, the first shape measurement sensor 41 melts the raw material powder (metal powder 13) with the energy beam 15 to form the bead 21. It is arranged on the front side in the scanning direction 17 of the modeling nozzle 10 with respect to the modeling nozzle 10 for forming. The second shape measurement sensor 42 is arranged on the rear side in the scanning direction 17 with respect to the modeling nozzle 10.

According to the configuration (9) above, it becomes easy to measure the first surface shape 61 by the first shape measurement sensor 41, and it becomes easy to measure the second surface shape 62 by the second shape measurement sensor 42.

(10) The modeling control device 100 according to at least one embodiment of the present disclosure includes the shape inspection device 101 having the configuration of any one of (2) to (9) above. The modeling control device 100 according to at least one embodiment of the present disclosure changes the initial path settings for realizing the final shape of the object 20 when the comparison unit 113 determines that the underfill area 300 exists. A path correction unit 103 configured to continue modeling according to bead correction path settings is provided.

According to the configuration (10) above, even if the underfill area 300 exists, modeling is continued according to the correction path settings, so that interruption of modeling is less likely to occur, and the time required for modeling is prevented from increasing. It can be suppressed.

(11) In some embodiments, in the configuration of (10) above, when the comparing unit 113 determines that the missing area 300 exists, the path correction unit 103 adds a path to fill the missing area 300. Modify path settings to set.

According to the configuration (11) above, even if the missing area 300 exists, the missing area 300 can be filled with the additional pass.

(12) In some embodiments, in the configuration of (11) above, the path correction unit 103 is configured such that the height of the bead 21 in the stacking direction is the same as the embodiment shown in FIGS. 8A and 8D. When the comparison unit 113 determines that the height in the stacking direction of the target shape 260 has not been reached, the correction path setting is set to add a stacking pass in the stacking direction.

According to the configuration (12) above, when the height of the bead 21 in the stacking direction does not reach the height of the bead 21 in the stacking direction in the target shape 260, or when the height of the aggregate 220 of the beads 21 does not reach the height of the aggregate Even if the height of the target shape 250 of 220 has not been reached, the height in the stacking direction can be corrected by an additional pass.

(13) In some embodiments, in the configuration of (11) or (12) above, the path correction unit 103 adjusts the size of the bead 21 in the width direction, as in the embodiment shown in FIGS. 8B and 8E. If the comparison unit 113 determines that the size of the bead 21 in the width direction has not reached the target shape 260 of the bead 21, the bead 21 adjacent to the bead 21 in the width direction (bead 25 in FIG. 8E or adjacent bead 26 in FIG. 8B) ) by setting the fix path settings to add the path to form the .

According to the configuration (13) above, even if the widthwise size of the bead 21 does not reach the widthwise size of the target shape 260 of the bead 21, the widthwise size is increased by the additional pass. It can be fixed.

(14) In some embodiments, in any of the configurations (10) to (13) above, the path correction portion has a size in the width direction of the bead 21, as in the embodiment shown in FIG. 8B. If the comparison unit 113 determines that the size of the bead 21 in the width direction in the target shape 260 has not been reached, the conditions for forming the bead 21 are changed so that the size of the bead 21 in the width direction becomes larger.

According to the configuration (14) above, the size in the width direction of the bead 21 (wide bead 27) formed after changing the formation conditions of the bead 21 satisfies the size in the width direction of the target shape 260 of the bead 21. You can prevent it from disappearing.

(15) A modeling device (three-dimensional modeling device 1) according to at least one embodiment of the present disclosure includes a modeling nozzle 10 for melting raw material powder (metal powder 13) with an energy beam 15 to form a bead 21; It includes a scanning unit 30 for scanning the modeling nozzle 10, and a modeling control device 100 having any of the configurations (10) to (14) above.

According to the configuration (15) above, even if the underfill area 300 exists, modeling is continued according to the correction path settings, so that interruption of modeling is less likely to occur, and the time required for modeling is prevented from increasing. It can be suppressed.

(16) The modeling control device 100 according to at least one embodiment of the present disclosure melts the raw material powder (metal powder 13) with the energy beam 15 according to the initial path settings for realizing the final shape of the modeled object 20. a comparison unit 113 that compares the shape of the bead 21 obtained by comparing the shape of the bead 21 with the target shape 260 of the bead 21 and determines whether there is an under-thickness area where the shape of the bead 21 does not reach the target shape 260 of the bead 21; Be prepared. When the comparison unit 113 determines that the underfill area 300 exists, the modeling control device 100 according to at least one embodiment of the present disclosure continues modeling according to the modified bead path settings that have been changed from the initial path settings. The path correction unit 103 is configured as follows.

According to the configuration (16) above, even if the underfill area 300 exists, modeling is continued according to the correction path settings, so that interruption of modeling is less likely to occur, and the time required for modeling is prevented from increasing. It can be suppressed.

1 3D modeling device 10 Modeling nozzle (nozzle device)
13 Metal powder 15 Energy beam 17 Scanning direction 20 Three-dimensional layered object (modeled object, workpiece)
21 Bead 30 Scanning section 41 First shape measurement sensor 42 Second shape measurement sensor 61 First surface shape 62 Second surface shape 65 Cross-sectional shape 100 Forming control device 101 Shape inspection device 103 Path correction section 105 Forming control section 110 Evaluation section 111 Bead shape calculation section 113 Comparison section 120 Target shape calculation section 220 Aggregate 250 Target shape 260 Target shape 300 Underfill area

Claims (12)

a first shape measurement sensor configured to move together with the modeling nozzle, which measures the first surface shape of the object before melting the raw material powder with an energy beam to form a bead;
a second shape measurement sensor configured to move together with the modeling nozzle, which measures a second surface shape of the shaped object after forming the bead;
an evaluation unit that evaluates the shape of the bead based on the first surface shape measured by the first shape measurement sensor and the second surface shape measured by the second shape measurement sensor;
Equipped with
The evaluation unit includes a bead shape calculation unit that calculates the shape of the bead ,
The bead shape calculation unit includes:
Calculating information on the three-dimensional shape of the first surface shape based on the first surface shape measured by the first shape measurement sensor and information on the scanning position of the modeling nozzle;
Calculating information on the three-dimensional shape of the second surface shape based on the second surface shape measured by the second shape measurement sensor and information on the scanning position of the modeling nozzle;
A three-dimensional shape of the bead is calculated from a difference between three-dimensional shape information of the first surface shape and three-dimensional shape information of the second surface shape.
Shape inspection device. The evaluation unit compares the shape of the bead calculated by the bead shape calculation unit with the target shape of the bead, and determines that there is an under-thickness area where the shape of the bead does not reach the target shape of the bead. The shape inspection device according to claim 1, further comprising a comparison section that determines whether or not. The shape inspection device according to claim 2, wherein the target shape of the bead is obtained based on CAD data of the shaped object. 4. The shape inspection apparatus according to claim 3, wherein the target shape of the bead is obtained based on CAD data of the object and a cutting allowance of the object after being formed. The shape inspection device according to claim 3 or 4, further comprising a target shape calculation unit that calculates the target shape of the bead. The first shape measurement sensor is disposed on the front side in the scanning direction of the modeling nozzle for forming the bead by melting the raw material powder with the energy beam,
The shape inspection device according to any one of claims 2 to 5 , wherein the second shape measurement sensor is arranged on the rear side in the scanning direction with respect to the modeling nozzle. A shape inspection device according to any one of claims 2 to 6 ,
When the comparing section determines that the under-thickness area exists, the modeling is configured to continue according to the modified path settings for the bead, which are modified from the initial path settings for realizing the final shape of the object. a path correction section,
A modeling control device comprising: The modeling control device according to claim 7 , wherein the path correction unit sets the correction path settings so as to add a pass to fill the missing area when the comparison unit determines that the missing area exists. . When the comparison unit determines that the height of the bead in the stacking direction does not reach the height in the stacking direction of the target shape of the bead, the path correction unit adds a pass for stacking in the stacking direction. The modeling control device according to claim 8 , wherein the correction path settings are set so as to. When the comparison unit determines that the size in the width direction of the bead does not reach the size in the width direction in the target shape of the bead, the path correction unit is configured to move the bead adjacent to the bead in the width direction. The modeling control device according to claim 8 or 9 , wherein the modified path setting is set to add a pass for forming a bead. When the comparison unit determines that the size in the width direction of the bead does not reach the size in the width direction in the target shape of the bead, the path correction unit adjusts the size in the width direction of the bead. The modeling control device according to any one of claims 7 to 10 , wherein conditions for forming the bead are changed so that the bead becomes larger. a shaping nozzle for melting the raw material powder with the energy beam to form the bead;
a scanning unit for scanning the modeling nozzle;
The modeling control device according to any one of claims 7 to 11 ;
A modeling device equipped with.

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