JP7744867B2 - Forming device, forming device unit, and forming system - Google Patents

Description

The present invention relates to a modeling apparatus , a modeling apparatus unit , and a modeling system .

Conventionally, a manufacturing method known as the Wire Arc Additive Manufacturing (WAAM) method is known, in which a three-dimensional object is manufactured by stacking molten metal using a welding manipulator (robot arm) (see, for example, Patent Document 1).
This manufacturing method allows for the creation of relatively large objects by supplying wire-like welding metal from an external source, as in MIG/MAG welding, and moving the robot arm using a transport device such as a cart, crane, or lifter.

Japanese Patent Application Laid-Open No. 2021-74981

However, in the above-mentioned modeling methods, the size of the object that can be modeled is limited by the range of motion of the transport device. For example, when an overhead crane is used to move the robot arm, the height of the model is limited to less than the installation height of the overhead crane.
The present invention has been made in view of the above circumstances, and aims to enable the creation of larger objects than ever before.

The molding apparatus according to the present invention comprises:
a moving mechanism that can move by adhering to a wall surface;
a metal lamination mechanism capable of laminating metal;
a control unit,
The control unit is configured to move the moving mechanism by adsorbing it to a wall surface, while causing the metal layering mechanism to shape the upper surface of the metal molded product .

This invention makes it possible to create larger objects than ever before.

FIG. 1 is a conceptual diagram illustrating a modeling system according to an embodiment. FIG. 1 is a perspective view of a modeling robot according to an embodiment. FIG. 2 is a view showing the periphery of the tip of the torch according to the embodiment. FIG. 2 is a block diagram showing a schematic control configuration of the molding system according to the embodiment. 1A to 1C are diagrams for explaining a forming process according to an embodiment. 1A to 1C are diagrams for explaining a forming process according to an embodiment.

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

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

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

Specifically, the modeling robot 10 includes a vehicle body 11 and a modeling mechanism 30 mounted on the vehicle body 11 .
The vehicle body 11 is an example of a moving mechanism according to the present invention, and includes a frame 12 on which the shaping mechanism 30 is mounted, and four wheels 18 that support the frame 12.
Each wheel 18 (wheel body) is formed in a spherical shape (spherical shell shape) and is rotatably supported by a rotation support part 13 provided on the frame 12. A drive part 16 that rotates each wheel 18 is fixed to the outside of each rotation support part 13. The drive part 16 is formed, for example, by a gear motor (geared motor) and is connected to the wheel 18. The drive part 16 is operated to rotate the wheel 18. This rotation allows the modeling robot 10 to travel on any surface.
The number of wheels 18 arranged is four in this embodiment, but is not limited to this.

Each wheel 18 also has a built-in electromagnet 19 (magnetic force generating means). The electromagnet 19 is configured so that its magnetic pole direction (direction of attractive force generation) can be changed independently of the rotation of the wheel 18 (outer shell) for movement. Such electromagnets 19 generate a magnetic force (attraction force) in a direction perpendicular to the contact surface of the wheel 18, providing traction for movement. Furthermore, the wheels 18 can be attracted to a metal wall surface and move along the wall. Note that the magnetic force generating means built into each wheel 18 is not limited to electromagnets as long as it is capable of changing its magnetic pole direction, and may be, for example, a permanent magnet.

The molding mechanism 30 is mounted on the frame 12 of the vehicle body 11. The molding mechanism 30 is an example of a metal laminating mechanism according to the present invention, and includes a torch 34 and a displacement mechanism 35 that supports the torch 34 so that it can be displaced.
The torch 34 is a work tool that uses arc discharge to melt a metal wire (filler material) W. The modeling robot 10 (modeling mechanism 30) melts and layers the metal wire W with the torch 34 using a welding method such as MIG, MAG, or TIG, thereby producing a three-dimensional metal model.

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

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

A rotation mechanism 354 is connected to the third movement mechanism 353. The rotation mechanism 354 is connected to the torch 34 via a connecting portion 355. The rotation mechanism 354 is a mechanism that rotates the torch 34 about a horizontal axis relative to the vehicle body 11.
The displacement mechanism 35 configured in this manner allows the position and attitude of the torch 34 to be changed as appropriate.

FIG. 3 is a diagram showing the periphery of the tip of the torch 34. As shown in FIG.
As shown in this figure, the imaging unit 37 is connected to and supported by the torch 34 via a connecting member 371. The imaging unit 37 is composed of, for example, a CMOS camera or a CCD camera, and captures an image of the object to be photographed, including the torch 34 and the wire W, and acquires the image information. The acquired image information is transmitted to the control device 4. The imaging unit 37 in this embodiment captures an image of the molten zone (the portion where the wire W is molten) around the torch 34 from diagonally above in the traveling direction (for example, the −Y direction) of the modeling robot 10.
The torch 34 also supports a laser beam irradiator 39. The laser beam irradiator 39 irradiates the periphery of the molten portion with a laser beam LB. In this embodiment, the laser beam irradiator 39 is disposed at the same position as the torch 34 in the X direction and adjacent to the torch 34 in the Y direction. This allows the laser beam LB from the laser beam irradiator 39 to be irradiated with its center at the same position as the torch 34 in the X direction. In addition, the laser beam irradiator 39 in this embodiment is configured to irradiate a line laser beam along the X direction as the laser beam LB. This allows the imaging unit 37 to accurately detect the shape of the formed metal or the like.

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

The position measurement device 110 measures the position of the modeling robot 10 itself. The specific configuration of the position measurement device 110 is not particularly limited, and it may, for example, be one that uses a Global Navigation Satellite System (GNSS). Alternatively, it may use a sensor that measures the traveling direction (such as an inertial measurement unit) and a traveling distance sensor to measure the position by sequentially integrating the direction and distance traveled over a very short period of time. Alternatively, it may measure the position of the modeling robot 10 by detecting reflectors (markers) placed at various locations in the work area with an optical sensor and comparing the detected reflectors with preset reflector placement information. Alternatively, it may calculate the position of the modeling robot 10 based on the position of the metal molded product obtained by image processing the results of capturing laser light LB with the imaging unit 37.

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

The CPU 41 operates each part of the control device 4 based on the operation content of the input unit 44, deploys programs pre-stored in the memory unit 42, and works in conjunction with the deployed programs to execute various processes.
The storage unit 42 is a memory configured by RAM (Random Access Memory), ROM (Read Only Memory), etc., and stores various programs and data, and also functions as a work area for the CPU 41. The storage unit of this embodiment stores a program for executing a formation process, which will be described later.

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

The wire feeder 5 is a mobile robot that supplies the wire W, electricity, and gas to the modeling robot 10 while following its movement. The wire feeder 5 holds a sufficient length of wire W, for example, wound on a wire reel (not shown). The wire feeder 5 is connected to the modeling robot 10 by a cable C1 of a predetermined length (e.g., up to approximately 10 m) and to an electricity and gas supply source (not shown) by a cable C2 of a sufficient length (e.g., up to several tens of meters) (see FIG. 1). The wire feeder 5 receives electricity and gas from the electricity and gas supply source via the cable C2 and supplies the wire W, electricity, and gas to the modeling robot 10 via the cable C1.
However, the wire feeder 5 may be movable independently of the modeling robot 10 and may at least supply the wire W to the modeling robot 10 .

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

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

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

Next, the CPU 41 operates the model-forming robot 10 based on the set movement path and melting timing of the model-forming robot 10 .
The control unit 102 of the modeling robot 10 operates each unit based on operation commands transmitted from the control device 4. As a result, the modeling robot 10 moves along a set movement path while supplying wire W downward from the tip (lower end) of the torch 34, melting and layering the wire W, and performing three-dimensional modeling. The position of the modeling robot 10 is acquired by the position measurement device 110 and transmitted to the control device 4. At this time, the wire feeder 5 supplies wire W, electricity, and gas to the modeling robot 10 while moving appropriately so as to be positioned within the length of the cable C1 from the modeling robot 10.

Here, the operation of the modeling robot 10 when manufacturing a cylindrical model will be specifically described.
5A, first, the modeling robot 10 melts and layers the wire W while traveling, for example, in a circular motion on the substrate S, and a circular metal molded object M is formed by solidifying the molten wire W. To give the metal molded object M a radial thickness, the modeling robot 10 may move in a circular motion with different radii.

When the height of the metal molding M exceeds the vertical movement range of the torch 34 after repeated stacking, as shown in Fig. 5(b), the modeling robot 10 attaches the wheels 18 to the wall surface and travels along the wall surface to further model the upper surface of the metal molding M. If the height position of the modeling robot 10 exceeds the length of the cable C1, as shown in Fig. 6(a), the wire feeder 5 also attaches the wheels 531 to the wall surface and travels along the wall surface.
This makes it possible to suitably form even a large, long cylindrical object, as shown in FIG. 6(b).

The shapes that the modeling robot 10 can model are not limited to cylindrical shapes. If the modeling robot 10 can move on a curved surface, it can freely model any curved shape, and it can even model shapes that are difficult to move on as long as the torch 34 can reach them.
Furthermore, the specific operation method of the modeling robot 10 is not particularly limited, and for example, a large model may be formed by multiple modeling robots 10 in a shared manner.

[Technical effect of this embodiment]
As described above, according to this embodiment, the modeling robot 10 includes the car body 11 that can move by adhering to a wall surface, and the modeling mechanism 30 that can stack metal.
This eliminates the limitations on model size imposed by the range of motion of the transport device, unlike the conventional method of moving the welding tool (robot arm) using a cart, crane, lifter, etc. Therefore, it is possible to create larger models than before.

Furthermore, according to this embodiment, the wire W or the like is supplied to the model-forming robot 10 from the wire feeder 5 that is movable independently of the model-forming robot 10 .
This eliminates the need to mount the wire W on the modeling robot 10 itself, and allows the wire feeder 5 to follow the modeling robot 10 and supply the wire W. Therefore, although the cable C1 that feeds the wire W to the modeling robot 10 cannot be made infinitely long due to factors such as friction of the wire W passing through it, by configuring the wire feeder 5 to be independently movable, the range of movement of the modeling robot 10 and, ultimately, the range of modeling sizes can be expanded.

[others]
Although the embodiments of the present invention have been described above, the present invention is not limited to the above-described embodiments.
For example, in the above embodiment, the control device 4 controls the operation of the model-forming robot 10, but the method of controlling the model-forming robot 10 is not particularly limited. The model-forming robot 10 may operate autonomously using a program or the like, or may be remotely controlled by an operator. When remotely controlled, it is preferable to display in real time on the display unit 45 an image of the welded portion around the torch 34 captured by the imaging unit 17 of the model-forming robot 10 so that the operator can see it.

In addition, in the above embodiment, the spherical wheels 18 are attached to the ground (wall surface) by magnetic force, but the shape of the wheels 18 and the type of adhesive force are not particularly limited. For example, the shape and structure of the wheels 18 may be barrel-shaped or may be a general rubber tire, or the wheels 18 may be attached to a surface by the adhesive force of their surfaces. The same applies to the wheels 531 of the wire feeder 5.

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

In the above embodiment, the wire feeder 5 is supplied with power and gas from the power and gas supply source, but the wire feeder 5 may be equipped with, for example, a power supply battery or a gas cylinder, which may supply power and gas to the modeling robot 10. Alternatively, the wire feeder 5 itself may be equipped with at least one of the wire W, a power supply, and gas, and the others may be supplied from an external supply source.
The specific configuration of the wire feeder 5 is also not particularly limited. For example, the wire feeder 5 may be rotatable like a turntable so as not to twist the cable C1 between the wire feeder 5 and the modeling robot 10, which moves in an arc, or may have an elevation mechanism so as to easily follow the height position of the modeling robot 10.

In the above embodiment, the metal lamination mechanism 30 capable of forming a shape by the so-called WAAM method has been described as an example of a metal lamination mechanism capable of laminating metal. However, the metal lamination mechanism according to the present invention is not limited to such a forming mechanism, and may suitably employ a method employed in a 3D printer, such as a method of hardening powder or liquid resin with a laser or the like.
Furthermore, the molding apparatus according to the present invention is not limited to those that create a molded object from scratch, but can also be suitably applied to those that repair a sunken hole or the like by molding, for example.

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

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

Claims (6)

a moving mechanism that can move by adhering to a wall surface;
a metal lamination mechanism capable of laminating metal;
a control unit,
The control unit causes the moving mechanism to move by adsorption to a wall surface, and shapes the upper surface of the metal molded object using the metal layering mechanism.
Modeling equipment. The metal lamination mechanism melts and laminates metal wires with a torch.
The molding apparatus according to claim 1 . The moving mechanism has a spherically formed wheel.
The molding apparatus according to claim 1 or 2. The wheel has built-in magnetic force generating means capable of changing the magnetic pole direction.
The molding apparatus according to claim 3 . The molding apparatus according to any one of claims 1 to 4,
a wire feeder configured to be movable independently of the modeling device and configured to store and supply a metal wire to the modeling device;
A molding device unit comprising: The molding apparatus according to any one of claims 1 to 4,
a control device that controls an operation of the molding device;
A molding system comprising: