WO2023248533A1

WO2023248533A1 - Film deposition condition generation device, film deposition device, film deposition condition generation method, film deposition method, and film deposition condition generation program

Info

Publication number: WO2023248533A1
Application number: PCT/JP2023/006271
Authority: WO
Inventors: 雅彦妻鹿; 裕貴小室; 紀幸榊原; 泰治鳥越; 芳史岡嶋
Original assignee: 三菱重工業株式会社
Priority date: 2022-06-21
Filing date: 2023-02-21
Publication date: 2023-12-28
Also published as: JP2024000746A

Abstract

The present invention suppresses film thickness from becoming non-uniform. This film deposition condition generation device includes: a predicted value calculation unit that calculates a predicted value of the film thickness of a coating sprayed on a workpiece using a thermal spray gun, such prediction being on the basis of parameters including the relative angle between the workpiece and the thermal spray gun, the distance from the thermal spray gun to the workpiece, the movement speed of the thermal spray gun relative to the workpiece, and the movement route of the thermal spray gun; and a parameter setting unit that sets a film deposition condition on the basis of the parameters used for calculation of the predicted value when the predicted value of the film thickness is within an allowable range, and that updates the parameters by an optimization calculation for film thickness when the predicted value of the film thickness is outside of the allowable range. The predicted value calculation unit uses the updated parameters to re-calculate the predicted value of the film thickness.

Description

Film-forming condition generation device, film-forming device, film-forming condition generation method, film-forming method, and film-forming condition generation program

The present disclosure relates to a film formation condition generation device, a film formation apparatus, a film formation condition generation method, a film formation method, and a film formation condition generation program.

The technology of coating products is known. For example, Patent Document 1 discloses a method for predicting the coating film thickness based on the spray film thickness, the spray distance, the moving speed of the spray gun, and the angle between the spray gun and the workpiece.

Japanese Patent Application Publication No. 2011-184778

However, depending on the shape of the workpiece, it may be necessary to overlap the passes of the thermal spray gun, which may cause the film thickness to become non-uniform.

The present disclosure has been made in view of the above, and provides a film thickness condition generating apparatus, a film forming apparatus, a film forming condition generating method, a film forming method, and a film forming condition generating apparatus capable of suppressing non-uniform film thickness. The purpose is to provide programs.

The film forming condition generation device according to the present disclosure includes a relative angle between a workpiece and a thermal spray gun, a distance from the thermal spray gun to the workpiece, a moving speed of the thermal spray gun with respect to the workpiece, and a moving path of the thermal spray gun. a predicted value calculation unit that calculates a predicted value of the thickness of a coating to be thermally sprayed on the workpiece using the thermal spray gun, based on parameters including; , setting film forming conditions based on the parameters used to calculate the predicted value, and updating the parameters by optimization calculation of the film thickness if the predicted value of the film thickness is outside the allowable range. The parameter setting unit and the predicted value calculation unit recalculate the predicted value of the film thickness using the updated parameters.

The film forming condition generation method according to the present disclosure includes a relative angle between a workpiece and a thermal spray gun, a distance from the thermal spray gun to the workpiece, a moving speed of the thermal spray gun with respect to the workpiece, and a moving path of the thermal spray gun. a predicted value calculation step of calculating a predicted value of a film thickness of a coating to be thermally sprayed on the workpiece using the thermal spray gun based on parameters including; and if the predicted value of the film thickness is within an allowable range; , setting film forming conditions based on the parameters used to calculate the predicted value, and updating the parameters by optimization calculation of the film thickness if the predicted value of the film thickness is outside the allowable range. In the parameter setting step and the predicted value calculation step, the predicted value of the film thickness is calculated again using the updated parameters.

A film forming condition generation program according to the present disclosure includes a relative angle between a workpiece and a thermal spray gun, a distance from the thermal spray gun to the workpiece, a moving speed of the thermal spray gun with respect to the workpiece, and a moving path of the thermal spray gun. a predicted value calculation step of calculating a predicted value of a film thickness of a coating to be thermally sprayed on the workpiece using the thermal spray gun based on parameters including; and if the predicted value of the film thickness is within an allowable range; , setting film forming conditions based on the parameters used to calculate the predicted value, and updating the parameters by optimization calculation of the film thickness if the predicted value of the film thickness is outside the allowable range. The parameter setting step and the predicted value calculation step cause the computer to calculate the predicted value of the film thickness again using the updated parameters.

According to the present disclosure, it is possible to suppress the film thickness from becoming non-uniform.

FIG. 1 is a schematic configuration diagram showing a film forming system of this embodiment. FIG. 2 is a schematic block diagram of the film forming apparatus. FIG. 3 is a diagram showing an example of a film forming method. FIG. 4 is a diagram showing an example of a film forming method. FIG. 5 is a block diagram of the film forming condition generation device. FIG. 6 is a schematic diagram for explaining parameters. FIG. 7 is a flowchart showing the processing of the film forming condition generation device. FIG. 8 is a schematic diagram showing an example of coating construction. FIG. 9 is a schematic diagram showing an example of coating when a workpiece has a protrusion.

Preferred embodiments of the present disclosure will be described in detail below with reference to the drawings. Note that the present disclosure is not limited to this embodiment, and if there are multiple embodiments, the present disclosure also includes a configuration in which each embodiment is combined. In addition, the components in the embodiments include those that can be easily imagined by those skilled in the art, those that are substantially the same, and those that are in the so-called equivalent range. Furthermore, the components in the embodiments described below can be omitted, replaced, or modified in various ways without departing from the gist of the present invention.

<Film forming system>
FIG. 1 is a schematic configuration diagram showing the film forming system of this embodiment.

In this embodiment, as shown in FIG. 1, the film forming system 1 includes a film forming apparatus 10, a film forming condition generating apparatus 11, a robot 12, a thermal spray gun 14, and a turntable 18.　　　

(Film forming equipment)
The film-forming device 10 is a device that applies a coating to a work W, which is a member to be coated, by controlling a robot 12 and a thermal spray gun 14 based on film-forming conditions set by a film-forming condition generating device 11. It is. The film forming apparatus 10 controls the robot 12 and the thermal spray gun 14 to spray the thermal spray material 20 onto the construction surface Wa of the workpiece W, and coats the construction surface Wa by solidifying the thermal spray material 20. Let it form.

FIG. 2 is a schematic block diagram of the film deposition apparatus. The film forming apparatus 10 is, for example, a computer, and as shown in FIG. 2, has a storage section 10A and a control section 10B. The storage unit 10A is a memory that stores calculation contents and program information of the control unit 10B, and includes, for example, a main storage device such as a RAM (Random Access Memory), a ROM (Read ONly Memory), and an HDD (Hard Disk). The storage device includes at least one external storage device such as a drive.

The control unit 10B is an arithmetic device and includes an arithmetic circuit such as a CPU (Central Processing Unit). The control section 10B includes a film formation condition acquisition section 10B1 and a film formation section 10B2. The control unit 10B reads and executes a program (software) from the storage unit 10A, thereby realizing a film-forming condition acquisition unit 10B1 and a film-forming unit 10B2, and executes these processes. Note that the control unit 10B may execute the process using one CPU, or may include a plurality of CPUs and execute the process using the plurality of CPUs. Further, at least a portion of the film forming condition acquisition section 10B1 and the film forming section 10B2 may be realized by a hardware circuit. Further, the program for the control unit 10B stored in the storage unit 10A may be stored in a storage medium readable by the film forming apparatus 10.

The film-forming condition acquisition unit 10B1 acquires the film-forming conditions set by the film-forming condition generation device 11. The film-forming conditions refer to conditions controlled by the film-forming unit 10B2 when coating the workpiece W. The film forming conditions in this embodiment include, for example, the moving speed of the thermal spray gun 14 with respect to the work W and the moving path of the thermal spray gun 14. For example, the film-forming condition acquisition unit 10B1 may acquire the film-forming conditions set by the film-forming condition generating device 11 via a communication unit (not shown), or may acquire the film-forming conditions set by the film-forming condition generating device 11. The film forming conditions may be acquired by inputting the film conditions to an input unit (not shown). Setting of film forming conditions by the film forming condition generation device 11 will be described later.

The film forming unit 10B2 applies a thermal spray material 20 to the construction surface Wa of the workpiece W based on the film forming conditions acquired by the film forming condition acquiring unit 10B1 (the film forming conditions set by the film forming condition generating device 11). A coating is applied on the construction surface Wa by thermal spraying. In the example of this embodiment, the film forming unit 10B2 controls the robot 12, the thermal spray gun 14, and the turntable 18 based on the film forming conditions to spray the thermal spray material 20 onto the construction surface Wa of the workpiece W. .

The robot 12 is a mechanism that changes at least one of the position and orientation of the thermal spray gun 14 under the control of the film forming apparatus 10 (film forming section 10B2). In this embodiment, the robot 12 changes both the position and orientation of the thermal spray gun 14. change. The robot 12 may be any mechanism capable of changing at least one of the position and orientation of the thermal spray gun 14, but is, for example, a vertically articulated six-axis robot, with the thermal spray gun 14 attached to the top.

The thermal spray gun 14 is a device that injects a thermal spray material 20 under the control of the film forming apparatus 10 (film forming section 10B2). The thermal spray gun 14 sprays the thermal spray material 20 onto the construction surface Wa of the workpiece W, which is placed at a position facing the thermal spray port 16 (see FIGS. 3 and 4) that injects the thermal spray material 20. Create a coating on Wa.

The turntable 18 is a mechanism that supports the workpiece W. The turntable 18 is a mechanism that changes at least one of the position and orientation of the instructed workpiece W under the control of the film-forming apparatus 10 (film-forming section 10B2), and in this embodiment, both the position and orientation of the workpiece W are changed. change. The turntable 18 may be any mechanism that changes at least one of the position and orientation of the workpiece W, but in the example of this embodiment, the construction surface Wa is directed to a position facing the thermal spraying port 16 of the thermal spraying gun 14. It is a table that rotates like this.

(Film forming method)
3 and 4 are diagrams showing an example of a film forming method.

As shown in FIG. 3, the thermal spray gun 14 has a base 15 and a thermal spray port 16 provided at the tip of the base 15 to inject the thermal spray material 20. As shown in FIG. 4, the film forming apparatus 10 (film forming section 10B2) sprays the thermal spray material 20 while moving the thermal spray gun 14 according to the moving path and moving speed indicated by the acquired film forming conditions. In the example of this embodiment, the moving route is set in a ladder shape as shown in FIG. 4, so the thermal spray gun 14 sprays the spray material 20 while moving in a ladder shape along the moving route. More specifically, in the example of FIG. 4, the movement path is a ladder that moves in one direction along the Y direction, then moves in the X direction by the length of pitch P, and then moves in the other direction along the Y direction. Although the trajectory is not limited to this, the movement route may be any trajectory.

(Film forming condition generation device)
FIG. 5 is a block diagram of the film forming condition generation device. The film forming condition generation device 11 is, for example, a computer, and includes an input section 40, an output section 42, a storage section 44, and a control section 46, as shown in FIG.

The input unit 40 is a mechanism that accepts operations by the user, and may be, for example, a mouse, a keyboard, a touch panel, etc. Alternatively, the parameters stored in the storage unit 44 may be read and automatically input. The output unit 42 includes a display device such as a display that displays images, and outputs processed information to the control unit 46 by the output control unit 52.

The storage unit 44 is a memory that stores various information such as calculation contents and programs of the control unit 46, and includes at least one of a RAM, a main storage device such as a ROM, and an external storage device such as an HDD. including. The program for the control unit 46 stored in the storage unit 44 may be stored in a storage medium that can be read by the film forming condition generation device 11.

The control unit 46 is a calculation device that sets film forming conditions, and includes a calculation circuit such as a CPU, for example. The control section 46 includes a predicted value calculation section 48, a parameter setting section 50, and an output control section 52. The control unit 46 reads a program (software) from the storage unit 44 and executes it to realize a predicted value calculation unit 48, a parameter setting unit 50, and an output control unit 52, and executes the processing thereof. . Note that the control unit 46 may execute these processes using one CPU, or may include a plurality of CPUs and execute the processes using the plurality of CPUs. Further, at least a part of the processing of the predicted value calculation section 48, the parameter setting section 50, and the output control section 52 may be realized by a hardware circuit.

(Predicted value calculation unit)
The predicted value calculation unit 48 calculates a predicted value of the film thickness of the coating formed by thermal spraying from the thermal spray gun 14 onto the workpiece W, based on parameters for calculating the predicted value. Specifically, the predicted value calculation unit 48 calculates the predicted value of the film thickness by executing an analysis (robot simulation) that simulates the operation of the thermal spray gun 14 using parameters for calculating the predicted value. do.

(obtaining parameters)
FIG. 6 is a schematic diagram for explaining parameters. The predicted value calculation unit 48 acquires parameters for calculating the predicted value. The predicted value calculation unit 48 obtains the relative angle φ, the distance D, the moving speed V, and the moving route as parameters. The relative angle φ refers to the angle formed between the workpiece W and the thermal spraying gun 14 in analysis, for example, the angle formed between the central axis of the thermal spraying port 16 of the thermal spraying gun 14 and the axis perpendicular to the construction surface Wa of the workpiece W. It can be an angle. Further, the distance D refers to the distance from the thermal spray gun 14 to the workpiece W in analysis, and may be, for example, the shortest distance from the thermal spraying port 16 of the thermal spraying gun 14 to the construction surface Wa of the workpiece W. Further, the moving speed V refers to the moving speed of the thermal spray gun 14 with respect to the workpiece W in analysis. Further, the moving route refers to information on the route along which the thermal spray gun 14 moves in analysis, and may be information indicating the position (coordinates) of the thermal spray gun 14 at each timing, for example.

In the present embodiment, the predicted value calculation unit 48 acquires the moving speed V and the moving route set by the parameter setting unit 50, which will be described later. Further, the predicted value calculation section 48 sets the relative angle φ and the distance D for each position of the thermal spray gun 14 along the movement path based on the movement path set by the parameter setting section 50. Specifically, the predicted value calculation unit 48 calculates the relationship between the thermal spray gun 14 and the workpiece W in the analysis for each position of the thermal spray gun 14 along the movement path based on the movement path and the position of the workpiece W in the analysis. determine whether it interferes. The predicted value calculation unit 48 calculates a case where the thermal spraying gun 14 and the workpiece W interfere when the thermal spraying gun 14 is moved along a set movement route while setting the relative angle φ and the distance D to predetermined values. In this case, it is determined that the thermal spray gun 14 and the work W will interfere, and if the thermal spray gun 14 and the work W do not interfere at that time, it is determined that the thermal spray gun 14 and the work W do not interfere. When the predicted value calculation unit 48 determines that the thermal spray gun 14 and the workpiece W do not interfere, the predicted value calculation unit 48 sets the relative angle φ and the distance D to predetermined values. On the other hand, when the predicted value calculation unit 48 determines that the thermal spray gun 14 and the workpiece W will interfere, it changes at least one of the relative angle φ and the distance D from a predetermined value. In other words, the predicted value calculation unit 48 maintains the relative angle φ and the distance D at predetermined values at the position of the thermal spray gun 14 that does not interfere with the work W, and maintains the relative angle φ and the distance D at predetermined values at the position of the thermal spray gun 14 that interferes with the work W. The angle φ and the distance D are made different from predetermined values. Note that the predetermined value may be any predetermined value, but in this case, when it is assumed that there will be no interference, the relative angle φ and the distance D are kept at predetermined values, and it is assumed that there will be interference. In this case, by shifting from the predetermined value, the actual operation of the thermal spray gun 14 can be simulated with high precision, and the predicted value of the film thickness can be calculated with high precision.

Note that the predetermined values for the relative angle φ and the distance D may be any predetermined values, and are preferably constant for each position of the thermal spray gun 14, for example. For example, the predetermined value of the relative angle φ is preferably 20 degrees to 30 degrees, but can be up to 45 degrees. In addition, when the relative angle φ and the distance D are set to be different from the predetermined values, the predicted value calculation unit 48 calculates the relative angle It is preferable to set φ and distance D. In other words, the predicted value calculation unit 48 preferably limits the degree of freedom between the relative angle φ and the distance D. The predetermined range here may be set arbitrarily, but for example, for the predetermined range of the relative angle φ, a value that is shifted by a maximum of 45 degrees in one direction with respect to the predetermined value may be shifted by a maximum of 45 degrees in the other direction. The range may be up to the specified value. Further, for example, the predetermined range of the distance D may range from a value 5% shorter than the predetermined value to a value 11% longer than the predetermined value. By restricting the degrees of freedom between the relative angle φ and the distance D in this way, the actual operation of the thermal spray gun 14 can be simulated with high precision, and the predicted value of the film thickness can be calculated with high precision. Furthermore, the predetermined values may be such that the relative angle φ and the distance D are determined in advance so that the thermal spray gun 14 does not interfere with any of the work W, and the moving speed V and the moving route may be adjusted during analysis.

It is also preferable that the moving speed V set by the parameter setting unit 50 be set within a predetermined range with respect to a predetermined value. The predetermined range here may be set arbitrarily, and may range from a value 33% lower than the predetermined value to a value 33% higher than the predetermined value, for example. By restricting the degree of freedom of the moving speed V in this manner, the actual operation of the thermal spray gun 14 can be simulated with high precision, and the predicted value of the film thickness can be calculated with high precision. Regarding the movement path (pitch P) among the parameters, the influence on the film thickness is close and easy to understand between the actual machine and the simulation, so there is no need to set it so that it falls within a predetermined range for a predetermined value. In other words, there is no need to set any particular restrictions.

(Calculation of predicted value)
The predicted value calculation unit 48 calculates the predicted value of the film thickness based on the parameters acquired as described above. That is, the predicted value calculation unit 48 executes an analysis simulating the thermal spraying gun 14 spraying the workpiece W according to the relative angle φ, distance D, moving speed V, and moving route indicated by the acquired parameters. Then, a predicted value of the coating thickness is calculated for each position on the construction surface Wa of the workpiece W. Specifically, the predicted value calculation unit 48 calculates the predicted value of the film thickness when the thermal spray gun 14 is stopped based on the obtained parameters using a film thickness prediction formula that predicts the film thickness when the thermal spray gun 14 is stopped. calculate. Then, the predicted value calculation unit 48 calculates the predicted value of the film thickness in the stopped state on the construction surface Wa so as to simulate that the thermal spray gun 14 moves according to the moving speed V and the moving route indicated by the parameters. By overlapping each position, a predicted value of the film thickness is calculated for each position on the construction surface Wa. Note that the film thickness prediction formula may be, for example, the one shown in the following formula (1).

T=T0・Δφ・ΔD・ΔV...(1)

Here, T is the predicted value of the film thickness. In addition, Δφ is a value indicating the degree of influence that the amount of deviation of the relative angle φ from a predetermined value has on the film thickness. Calculated based on Further, ΔD is a value indicating the degree of influence that the amount of deviation of the distance D from a predetermined value has on the film thickness, for example, based on a preset coefficient and the amount of deviation of the distance D from a predetermined value. Calculated. Further, ΔV is a value indicating the degree of influence that the amount of deviation of the moving speed V from a predetermined value has on the film thickness. Calculated based on Further, T0 is a reference value of the film thickness, and is a predicted value of the film thickness when the relative angle φ, the distance D, and the moving speed V are predetermined values. A preset value may be used for T0. Using the film thickness calculation formula (1), it is possible to obtain cross-sectional film thickness information of one line of film formation. Since the overall film thickness is formed by overlapping the stripes, it is calculated based on the pitch P (distance between adjacent movement paths). That is, by overlapping one line of the film-formed portion calculated using equation (1) at each pitch P, the entire film thickness can be calculated.

Note that it is preferable that the predicted value calculation unit 48 calculates not only the predicted value of the film thickness but also the predicted value of the construction time required for coating. The construction time here refers to the time from the start to the end of thermal spraying, and is calculated together with the predicted value of the film thickness by the above-mentioned analysis.

(Parameter setting section)
The parameter setting unit 50 sets parameters for recalculating the predicted value of the film thickness based on the predicted value of the film thickness calculated by the predicted value calculating unit 48.

(Resetting parameters)
The parameter setting unit 50 determines whether the predicted value of the film thickness calculated by the predicted value calculation unit 48 is within the allowable range, and if it is outside the allowable range, the parameter setting unit 50 determines whether the predicted value of the film thickness calculated by the predicted value calculating unit 48 is within the allowable range. Reset parameters (update parameters). For example, when at least one of the film thicknesses at each position on the construction surface Wa is outside the permissible range, the parameter setting unit 50 may determine that the predicted value of the film thickness is outside the permissible range; If all of the values are within the allowable range, it may be determined that the predicted value of the film thickness is not allowable. The allowable range here may be set arbitrarily. In this embodiment, the parameter setting unit 50 resets the moving speed V and the moving route among the parameters used to calculate the predicted value of the film thickness. The parameter setting unit 50 uses a particle swarm optimization method as the optimization calculation. For example, the parameter setting unit 50 sets the allowable value of the film thickness as a constraint (penalty function p(x)), and sets the variation in the predicted value of the film thickness for each position as an objective function f(x), and sets an evaluation function g(x). The moving path and moving speed V that minimize =f(x)+a·p(x) are calculated and used as values for recalculating the predicted value of the film thickness. It is preferable that the parameter setting unit 50 sets the moving speed V so that it falls within a predetermined range with respect to a predetermined value. The predetermined range here may be set arbitrarily, and may be, for example, a range from a value 33% lower than the predetermined value to a value 33% higher than the predetermined value. On the other hand, the parameter setting unit 50 does not need to set the movement path (pitch P) so that it falls within a predetermined range with respect to a predetermined value, in other words, it does not need to limit the degree of freedom.

The predicted value calculation unit 48 calculates the predicted value of the film thickness by performing analysis using the above-described method using the parameters reset by the parameter setting unit 50 (here, the moving speed V and the moving route). The predicted value calculation unit 48 and the parameter setting unit 50 repeat this process until the predicted value of the film thickness falls within the allowable range. Note that, for example, a predetermined value may be used as a parameter when the predicted value calculation unit 48 first calculates the predicted value of the film thickness.

(Setting film forming conditions)
If the predicted value of the film thickness calculated by the predicted value calculation unit 48 is within the allowable range, the parameter setting unit 50 sets the film forming conditions based on the parameters used to calculate the predicted value. . In this embodiment, the parameter setting unit 50 sets the parameters themselves used to calculate the predicted value of the film thickness that falls within the allowable range as the film forming conditions. Specifically, the parameter setting unit 50 sets the moving path and moving speed V used to calculate the predicted value of the film thickness that is within the allowable range as the film forming conditions. However, the present invention is not limited thereto, and a value obtained by adjusting the parameters used to calculate the predicted value of the film thickness that falls within the allowable range may be set as the film forming condition.

(output control section)
The output control unit 52 transmits information on the film forming conditions set by the parameter setting unit 50 to the film forming apparatus 10. The film forming apparatus 10 performs coating based on the film forming conditions transmitted from the output control unit 52.

<Processing flow>
Next, the processing flow of the film forming condition generation device 11 will be explained using FIG. 7. FIG. 7 is a flowchart showing the processing of the film forming condition generation device.

The film forming condition generation device 11 obtains parameters using the predicted value calculation unit 48 (step S12). In this embodiment, the predicted value calculation unit 48 acquires the moving speed V and the moving route set by the parameter setting unit 50, and calculates the relative angle φ and distance based on the moving route set by the parameter setting unit 50. Set D.

The film forming condition generation device 11 uses the predicted value calculation unit 48 to calculate a predicted value of the film thickness based on the parameters (step S14). Specifically, the predicted value calculation unit 48 calculates the predicted value of the film thickness and the predicted value of the construction time by performing analysis based on the parameters.

The film forming condition generation device 11 uses the parameter setting unit 50 to determine whether the predicted value of the film thickness is within an allowable range (step S16). The allowable range may be set arbitrarily, and may be set in advance by an operator, for example. When the parameter setting unit 50 determines that the predicted value of the film thickness is outside the allowable range (step S16; No), the parameter setting unit 50 updates the parameters by optimization calculation (step S18). Specifically, the parameter setting unit 50 sets the moving speed V and the moving route. Thereafter, the process returns to step S12, and the predicted value calculation unit 48 uses the updated parameters to recalculate the predicted value of the film thickness.

When the film-forming condition generation device 11 determines that the predicted value of the film thickness is within the allowable range (step S16; Yes), it sets the film-forming conditions based on the parameters used for the predicted value (step S20). ).

Note that in the above description, the film forming condition generating device 11 that sets film forming conditions and the film forming device 10 that performs film forming based on the film forming conditions are different devices. However, the present invention is not limited thereto, and the film-forming condition generation device 11 and the film-forming device 10 may be the same device. That is, for example, the film forming apparatus 10 has the functions of the film forming condition generating apparatus 11, executes the processes of the predicted value calculation unit 48 and the parameter setting unit 50, sets the film forming conditions, and also sets the film forming conditions. Film formation may be performed based on the above.

Next, construction examples will be explained. FIG. 8 is a schematic diagram showing an example of coating construction.

As shown in FIG. 8, the film forming apparatus 10 may form a coating 30a in a range of a movement path 32a, and may form a coating 30b in a range of a movement path 32b that partially overlaps the movement path 32a. . In this way, when the moving paths 32b overlap, there is a risk that the film thickness will become uneven due to overlapping film formation.However, as in this embodiment, when the predicted value of the film thickness is calculated By repeating optimization calculations and setting the film forming conditions, it is possible to assume in advance the case where the movement paths overlap, and to determine the film forming conditions so that the film thickness does not become non-uniform.

FIG. 9 is a schematic diagram showing an example of coating when the workpiece has a protrusion.

As shown in FIG. 9, a workpiece W having a shape in which a protrusion 60 protrudes from the construction surface Wa may be coated. In such a case, the moving path becomes more complicated than when coating a flat plate as shown in FIG. 8, and the film thickness tends to become non-uniform. For example, as shown in the

movement paths

32a and 32b in FIG. 9, it becomes more necessary to overlap the movement paths, and the film thickness tends to become particularly non-uniform. On the other hand, as in this embodiment, by repeatedly calculating the predicted value of the film thickness and performing optimization calculations to set the film forming conditions, the film thickness is The film forming conditions can be determined so that the film does not become non-uniform. Specifically, in the region AR where the moving path 32a and the moving path 32b overlap, if the film is formed at the same moving speed and the same pitch, the film thickness will almost double. In order to make the increased film thickness uniform, for example, the movement path 32b accelerates from a position 32bA, decelerates from a position 32bB that passes through the area AR, and turns back outside the construction surface Wa. When turning around, the vehicle accelerates from position 32bB and decelerates from position 32bA. By decelerating in the region AR in this manner, the film thickness can be adjusted. The same applies to the moving route 32a. However, the robot 12 cannot perform sudden acceleration or deceleration. Particularly, in thermal spray film formation, the robot 12 is required to move at a high speed relative to its ability, and variations in film thickness are likely to occur in areas where there is acceleration and deceleration (positions 32aA, 32bA). Therefore, if early acceleration is instructed in order to ensure the acceleration of the area AR, the area in front of the positions 32aA and 32bA becomes thinner. On the other hand, if the acceleration instruction is too slow, a thick film pressure will occur in the region AR. With the acceleration and deceleration capabilities of current industrial robots, it is almost impossible to completely equalize the film thickness using speed alone, but as in this embodiment, it is possible to optimize both the pitch P and the movement speed V. Depending on the required value, it can be placed within an acceptable error range. However, in the case of complex phenomena, manual control is almost impossible. On the other hand, in robot simulation, the actual speed can be predicted based on the above-mentioned acceleration/deceleration ability, so the film thickness distribution can also be predicted based on the prediction. Based on the simulation results as in this embodiment, by using a method of repeating the procedure of resetting the moving speed V and pitch P in the optimal direction, the instruction values for the robot that will optimize the film thickness distribution are predicted. be able to.

<Effect>
The film forming condition generation device 11 according to the first aspect of the present disclosure determines the relative angle φ between the work W and the thermal spray gun 14, the distance D from the thermal spray gun 14 to the work W, and the moving speed of the thermal spray gun 14 with respect to the work W. a predicted value calculation unit 48 that calculates a predicted value of the film thickness of the coating to be thermally sprayed onto the workpiece W using the thermal spray gun 14 based on parameters including V and the movement path of the thermal spray gun 14; If the value is within the allowable range, the film forming conditions are set based on the parameters used to calculate the predicted value, and if the predicted value of the film thickness is outside the allowable range, the film forming conditions are set. The parameter setting unit 50, which updates parameters through optimization calculation, and the predicted value calculation unit 48 use the updated parameters to calculate the predicted value of the film thickness again.

According to the present disclosure, the film thickness can be made uniform. Further, it is possible to suppress local thinning of the film thickness.

Furthermore, in thermal spray film formation, it is necessary to move the thermal spray gun at high speed, and control over the processed surface that requires acceleration and deceleration may exceed the capability of the thermal spray gun. In such a case, the movement speed may not be as instructed, and furthermore, the teaching point, which is the movement route, may not move as instructed (the thermal spray gun takes a shortcut, etc.). Programming that takes into account variations caused by the gun's capabilities is not possible. Therefore, non-uniformity in film thickness is particularly likely to occur in areas where movement paths overlap, such as the area AR in FIG. 9, for example. On the other hand, according to the present embodiment, the parameters are set by analysis that takes into account the ability of the thermal spray gun, so it is possible to appropriately reflect the ability of the thermal spray gun and make the film thickness uniform.

Furthermore, since the movement path of the thermal spray gun may be set so as to turn back over the processing surface, unless the turn-back time is shortened, the construction time will be extended, which may increase costs and man-hours. On the other hand, if the folding points are placed too close together in order to shorten the folding time, the film thickness at the edge of the processed surface will be affected. Therefore, it is necessary to optimize the turning point. On the other hand, according to the present embodiment, by setting a travel route including the turning points, it is possible to optimize the turning points as well.

Additionally, if the thicker film slightly exceeds the tolerance due to variations in film thickness, it is possible to bring it within the tolerance by polishing the exceeded portion. On the other hand, if the film thickness is thinner than the allowable value, it is necessary to perform additional film formation, but additional film formation requires more steps and costs than polishing. Therefore, even if the actual film thickness is slightly outside the allowable range, it is better to eliminate additional film formation and perform polishing. In other words, for example, even if the machined surface is complex and the entire surface cannot be kept within the allowable range, the film formation conditions should be set so that at least it can be thicker than the allowable range and thinner than the allowable range. be able to. This makes it possible to suppress a significant increase in man-hours and costs.

The film-forming condition generating device 11 according to the second aspect of the present disclosure is the film-forming condition generating device 11 according to the first aspect, in which the parameter setting unit 50 determines the moving speed V of the parameters by optimization calculation. and a travel route. According to the present disclosure, the accuracy of making the film thickness uniform can be improved.

The film-forming condition generating device 11 according to the third aspect of the present disclosure is the film-forming condition generating device 11 according to the first aspect or the second aspect, and the predicted value calculation unit 48 calculates the relative angle φ, the distance D, and The predicted value of the film thickness is calculated under the condition that the moving speed V falls within a predetermined range. According to the present disclosure, both the condition range to be predicted and the prediction accuracy can be improved.

The film-forming condition generating device 11 according to the fourth aspect of the present disclosure is the film-forming condition generating device 11 according to any of the first to third aspects, in which the predicted value calculation unit 48 For each position of the thermal spraying gun 14, it is determined whether the thermal spraying gun 14 and the workpiece W will interfere, and the relative angle φ and distance D at the position where it is determined that there will be no interference are kept at predetermined values, and at the position where it is determined that there will be interference. A predicted value of the film thickness is calculated under conditions in which at least one of the relative angle φ and the distance D is made different from a predetermined value. According to the present disclosure, even if the projection protrudes from the construction surface, the film thickness around the joint can be made uniform. Further, even if there are obstacles that interfere with the thermal spray gun around the construction surface, the film thickness can be made uniform.

The film formation condition generation device 11 according to the fifth aspect of the present disclosure is the film formation condition generation device 11 according to any one of the first to fourth aspects, and the predicted value calculation unit 48 calculates the construction time required for coating. The predicted value of is also calculated. According to the present disclosure, construction time can be grasped, leading to reduction in man-hours.

The film-forming condition generation device 11 according to the sixth aspect of the present disclosure is the film-forming condition generation device 11 according to any of the first to fifth aspects, in which the parameter setting unit 50 performs particle Use group optimization method. According to the present disclosure, the accuracy of making the film thickness uniform can be improved.

The film forming apparatus 10 of the present disclosure performs film forming based on the film forming conditions set by the film forming condition generating apparatus 11 according to any one of the first to sixth aspects. According to the present disclosure, the predicted film thickness can actually be formed on the construction surface of the workpiece.

The film forming condition generating method of the film forming condition generating apparatus 11 of the present disclosure is based on the relative angle φ between the work W and the thermal spray gun 14, the distance D from the thermal spray gun 14 to the work W, and the movement of the thermal spray gun 14 with respect to the work W. a predicted value calculation step of calculating a predicted value of the thickness of the coating to be thermally sprayed onto the workpiece W using the thermal spray gun 14 based on parameters including the speed V and the movement path of the thermal spray gun 14; and a prediction of the coating thickness. If the value is within the allowable range, the film forming conditions are set based on the parameters used to calculate the predicted value, and if the predicted value of the film thickness is outside the allowable range, the film forming conditions are set. In the parameter setting step of updating parameters by optimization calculation and the predicted value calculation step, the predicted value of the film thickness is calculated again using the updated parameters.

The film forming method of the present disclosure executes film forming based on the film forming conditions set by the film forming condition generation method. According to the present disclosure, the predicted film thickness can actually be formed on the construction surface of the workpiece.

The film forming condition generation program of the film forming condition generating apparatus 11 of the present disclosure includes the relative angle φ between the workpiece W and the thermal spraying gun 14, the distance D from the thermal spraying gun 14 to the workpiece W, and the movement of the thermal spraying gun 14 with respect to the workpiece W. a predicted value calculation step of calculating a predicted value of the thickness of the coating to be thermally sprayed onto the workpiece W using the thermal spray gun 14 based on parameters including the speed V and the movement path of the thermal spray gun 14; and a prediction of the coating thickness. If the value is within the allowable range, the film forming conditions are set based on the parameters used to calculate the predicted value, and if the predicted value of the film thickness is outside the allowable range, the film forming conditions are set. The parameter setting step of updating parameters by optimization calculation and the predicted value calculation step cause the computer to calculate the predicted value of the film thickness again using the updated parameters.

10 Film forming device 11 Film forming condition generating device 14 Thermal spray gun 48 Predicted value calculation unit 50 Parameter setting unit D Distance V Traveling speed W Workpiece φ Relative angle

Claims

The thermal spray gun is controlled based on parameters including a relative angle between the workpiece and the thermal spray gun, a distance from the thermal spray gun to the workpiece, a moving speed of the thermal spray gun with respect to the workpiece, and a moving path of the thermal spray gun. a predicted value calculation unit that calculates a predicted value of the film thickness of the coating to be thermally sprayed on the work using the
If the predicted value of the film thickness is within the allowable range, the film forming conditions are set based on the parameters used to calculate the predicted value, and if the predicted value of the film thickness is outside the allowable range. a parameter setting unit that updates the parameters by the film thickness optimization calculation;
The predicted value calculation unit recalculates the predicted value of the film thickness using the updated parameters.
Film forming condition generation device.
The parameter setting unit sets the moving speed and the moving route among the parameters by optimization calculation.
The film forming condition generation device according to claim 1.
The predicted value calculation unit calculates the predicted value of the film thickness under conditions where the relative angle, the distance, and the moving speed fall within a predetermined range.
A film forming condition generation device according to claim 1 or claim 2.
The predicted value calculation unit includes:
determining whether the thermal spraying gun and the workpiece interfere with each other along the movement path for each position of the thermal spraying gun;
the relative angle and the distance at a position determined not to interfere are kept at predetermined values, and at least one of the relative angle and the distance at a position determined to interfere is made to differ from the predetermined value; Calculate the predicted value of film thickness,
A film forming condition generation device according to claim 1 or claim 2.
The predicted value calculation unit also calculates a predicted value of the construction time required for coating.
A film forming condition generation device according to claim 1 or claim 2.
The parameter setting unit uses a particle swarm optimization method as the optimization calculation.
A film forming condition generation device according to claim 1 or claim 2.
Performing film formation based on the film formation conditions set by the film formation condition generation device according to claim 1 or 2.
Film deposition equipment.
The thermal spray gun is controlled based on parameters including a relative angle between the workpiece and the thermal spray gun, a distance from the thermal spray gun to the workpiece, a moving speed of the thermal spray gun with respect to the workpiece, and a moving path of the thermal spray gun. a predicted value calculation step of calculating a predicted value of the film thickness of the coating to be thermally sprayed on the workpiece using the method;
If the predicted value of the film thickness is within the allowable range, the film forming conditions are set based on the parameters used to calculate the predicted value, and if the predicted value of the film thickness is outside the allowable range. a parameter setting step of updating the parameters by the film thickness optimization calculation;
The predicted value calculation step includes recalculating the predicted value of the film thickness using the updated parameters.
Method for generating film-forming conditions.
Performing film formation based on the film formation conditions set by the film formation condition generation method according to claim 8.
Film formation method.
The thermal spray gun is controlled based on parameters including a relative angle between the workpiece and the thermal spray gun, a distance from the thermal spray gun to the workpiece, a moving speed of the thermal spray gun with respect to the workpiece, and a moving path of the thermal spray gun. a predicted value calculation step of calculating a predicted value of the film thickness of the coating to be thermally sprayed on the workpiece using the method;
If the predicted value of the film thickness is within the allowable range, the film forming conditions are set based on the parameters used to calculate the predicted value, and if the predicted value of the film thickness is outside the allowable range. a parameter setting step of updating the parameters by the film thickness optimization calculation;
The predicted value calculation step includes recalculating the predicted value of the film thickness using the updated parameters;
make the computer execute
Film formation condition generation program.