JPH0755538B2 - Computer-aided manufacturing method and apparatus - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION Conventionally, computer aided design (CAD) devices have been proposed. With the help of a computer, an operator can design a two-dimensional or three-dimensional object and display the design on a screen or paper. The computer assists in the overall design required by the operator according to existing design parameters or computer software. One such computer-aided design device is manufactured by Vector Automation of Baltimore, MD as the Cadmax II.

It has also been proposed to control machine operations or manufacturing processes by computer, as in robotics. Robots or remote gripper jaws are operated by pre-programmed computers to perform specific operations or tasks. For example, milling metal parts to produce simple articles using computer-aided milling machines is widely applied. One such computer-aided milling machine is the one manufactured by Cincinnati Millicron Company. Another example of computer-aided machine operation is spray painting of objects with a computer controlled spray gun arm,
The spray gun arm moves the spray gun in a predetermined pattern to repetitively and evenly coat an object on the assembly line. For example, Texas,
Richardson's Thermwood Corporation
It manufactures an industrial robot for computerized painting called Paint Master.

3D reproduction of designs from photographs and grid charts has been used to automatically engrave or carve 3D objects from large materials, as previously disclosed in US Pat. Nos. 3,988,520 and 1,382,978. Has been proposed in the field of photo engraving.

According to one aspect of the invention, there is provided the following method: a method for designing an article in two dimensions and then replicating the article in three dimensions, the method comprising: Steps of generating a data file of the three-dimensional coordinates shown in a computer machine, giving a controlled environment, giving a species serving as a starting point in the coordinate system to the controlled environment, providing a source of collective particles, supplying particles Directing from the source to the three-dimensional coordinates of the article in the coordinate system, placing the particles in the coordinates, and connecting the particles to each other in the coordinates 3 around the progenitor species.
A computer-aided manufacturing method comprising the steps of making a dimensional article.

According to another aspect of the invention, the following apparatus is provided: means for replicating a tangible three-dimensional article from a data file created by a computer machine for designing the article, the means comprising: , 3D coordinate system and design of articles between rooms 3
Data file with dimensional coordinate information, control environment, tangible species that serve as the origin of the three-dimensional coordinate system, means for locating species in the control environment at the origin of the coordinate system, source of collective particles, source of collective particles Directional means for directing to the coordinates of the coordinate system in the control environment, control means for controlling the directivity means in accordance with the coordinate information of the data file, and collective particles connected in the coordinates at three-dimensional around the seed. A computer-aided manufacturing apparatus comprising: means for physically configuring an article.

Such a method and apparatus can, with the aid of a computer, automatically replicate a physical three-dimensional article designed from a computer data file.

Three-dimensional articles can be manufactured by increasing the grain from a single seed corresponding to a computer data file of the design.

The particle directed beam directs and fixes the position of the particles according to a predetermined coordinate system and a data file or coordinate information corresponding to the design generated by the computer machine.

Thus, the article is one of these three in computer aided design.
It is designed by a computer machine that generates a data file of coordinate information indicating dimensional coordinates. The data file coordinates are sent to and input into a programmed controller that controls the servomechanism. The servo mechanism thus controls the movable ejection head, which directs the particles to the coordinates of the three-dimensional object in the three-dimensional coordinate system by means of propulsive or absorbing forces. A tangible species that attracts particles and constructs an object from that point is placed at the origin of the coordinate system in the controlled environment. The beam may be an emission of particles or an emission of drops containing particles, or it may be an energy beam that attracts particles already in its environment to the seed or other coordinates. By moving the machine head under computer control according to the coordinate information indicating the design, a tangible three-dimensional article or object can be automatically constructed and manufactured according to the design created from the origin of the seed.

The invention is schematically illustrated by way of example in the accompanying drawings.

Drawings Referring first to FIG. 1, an article 10 in the form of a cup
Is shown to be designed on a computer system including a computer machine 14 for designing an article 10 at the direction of a draftsman or designer. Computer machine 14 may be a machine such as those used in computer-aided design.

In a typical computer-aided design (CAD) device, the designer uses normal conversation to speak to a computer machine with a data tablet or keyboard. The designer directs the machine to create, measure, rotate, modify and / or sort various elements of his design or drawing. The computer machine interprets the instructions, accomplishes the task ordered, displays the results on the terminal CRT, and responds by compiling the data file corresponding to the created and displayed design.
Once the drawing and design work is complete, the data file containing the coordinate information corresponding to the created design is stored on a hard disk or other computer storage medium for permanent storage.

In the method and apparatus of the present invention, a data file, generally in the form of coded binary information, is transferred to a machine controller 16 which is part of computing device 12. Appropriate computer software is used to convert this coded binary information into a machine control language for input to machine controller 16. The machine controller 16 includes a pair of servo mechanisms 20 and
To control 22, it sends signals in much the same way that current technology uses to control robots and other mechanical devices. Controlling a machine utilizing a computer, commonly referred to as computer-aided manufacturing (CAM), is available in many machines that are generally incorporated as machine controller 16.

The computer machine 14 that designs the article and the machine controller 16 that controls the servo mechanism in response to the three-dimensional coordinate data file created by the machine 14 are any suitable conventional available CAD and CAM machines. Good. On the other hand,
The computer device 12 may include an integrated computer machine incorporating both computer design machine and computer machine cotroller functionality, as will be apparent to those skilled in the art.

The servomechanism 20 is a working head 24 which is any suitable ejection head having an ejection nozzle for ejecting small ensemble particles or droplets of granules by a suitable mechanical linkage.
To control.

The second work head 26, which is a suitable ejection head,
It is controlled by the servo mechanism 22. Work heads 24 and 26
Any conventional servomotor and motion transfer mechanism can be used to move the. For example, a servo mechanism 20 controlled by an electric signal from the machine controller 16,
It is possible to use an electric servomotor with 22. Then, the electric servomotor is operated by the machining injection heads 24 and 26.
Control the position of.

As shown, a spatial device for replicating a three-dimensional article is schematically illustrated in the form of a polar coordinate system having a polar surface 30, in which the injection head of the working head 26 is a coordinate system. A circular passage is moved around the origin 0 of the tangent, and the tangible seed 32 is placed at the origin 0. Seed 32 is at the point at which the physical fabrication of article 10 begins, as described in detail below. The head 26 moves radially and vertically up and down in the pole face.

Separated above the polar surface 30 and parallel to the polar surface 30, an XY coordinate plane
36, in which the injection head of the working head 24 moves according to the X and Y coordinates. The head 24 is moved by the servomechanism 20 according to the three-dimensional coordinates of the data file created in response to the computer design of the article 10. It should be understood that the article 10 is designed in the same coordinate system in which the article 36 is replicated, as would be apparent to one of ordinary skill in the computer arts after the method and apparatus of the present invention have been taught. Is.

Seed 32 is secured to location 38 within controlled environment 40 by any suitable structural means. The nature of the controlled environment 40 depends on the type of granules used to make the tangible article 34. For example, the mass particles can be a ceramic material, and the controlled environment will include an atmosphere that is heated to the desired temperature. The collective particles are directed to the coordinates of the three-dimensional article,
Then, it is stored in the data file 18. The ceramic particles collide and first adhere to the seed 32 and then collide with each other in the coordinates of the article 34. Subsequent particles will adhere to each other,
The article is made according to the three-dimensional coordinates contained in the data file 18 and the program of the machine controller 16.
The program for replicating the article may be any suitable software developed according to current know-how and apparent to those skilled in the art.

2A-2C, the manufacture of a three-dimensional article 34 designed in three dimensions with the aid of a computer machine is illustrated at different stages of manufacture. As shown in FIG. 2A, the first particles 42 are directed to the seed 32 and impact and adhere to the seed 32. The first particle is the seed
It comes from the XY head 24 so that it directly impacts the top of 32. The second and subsequent particle, the bottom 36 of the wall 36 b of the cup
The heads 24 and 26 are ejected in any number of combinations according to the control provided by the machine controller 16 to create a. For example, the second particles 44, are ejected from the working head directly onto the particles 42 and are joined thereto by any physical adhesive or bonding means. Figure 2B, after the bottom 36 a is partially formed, and shows the article 34 in the side wall 36 b is manufactured. The 2C diagram illustrates the final stage of the cup wall 36 b is article 36 of the most manufactured in finished state.

It should be understood that other materials can be used to make the tangible article. For example, it is also possible to use, for example, plastic materials in current ionizing atmospheres as in current electrostatic coating technology. Additional glue can also be used to bond the particles together,
Alternatively, they fuse due to their chemical nature.
Moisture containing slurry materials can be used and the controlled environment can include a closed environment cooled to sub-zero temperatures such that the particles impact each other and the species and freeze.

The heads 24, 26 emit an energy beam in the form of particles for impinging and adhering to each other to the coordinates, or the beam attracts the particles to the coordinates for impinging and adhering to each other. For example, more than one machining head can be used, which emits directed energy beams that intersect each other at the intersections. The beam is controlled according to the servomechanisms 20, 22 and the machine controller so that the intersection points are located at the coordinate points of the three-dimensional object being manufactured. The energy beam may be an electromagnetic beam and the enclosed environment may contain magnetized particles that are attracted to the intersections of the electromagnetic beams. In other devices, the working head may be a laser gun that emits a laser beam, the laser beams intersect at points of intersection with each other, and the particles are ejected in a closed atmosphere of a controlled environment such that the coordinates fuse. Generates enough heat to melt.

Seed 32 may be any suitable material, for example a metal such as steel, or a ceramic material in the case of a ceramic system. In the case of slurries and laser systems, metallic materials are probably the most advantageous. In the case of electrostatically attracting ionic systems, metal or plastic materials are for example suitable, and in magnetic systems metallic materials can be used.

In all of the above chemical and mechanical systems, controlling the working head to orient the particles into coordinates for impact bonding with one another will be entirely apparent to those skilled in the computer and control arts.

3 and 4 show multiple directional beams 50, 52 and 54.
Figure 5 illustrates a device having a plurality of directional means for emitting light. Shown therein is a chamber 56 that forms a controlled environment in which the seed 32 is secured. The directional means comprises three work heads 58, 60 and 62 which are controlled by servomechanisms 64, 66 and 68, respectively. Servo mechanism servo motor is programmed controller 16
Controlled by. The work heads 58, 60, 62 can be moved in their respective planes to create a crossing beam having an intersection at the desired coordinates shown in the desired coordinates, and are illustrated in FIGS. 3 and 4. Coordinate system is X,
It is a standard Cartesian coordinate system having Y and Z axes. In this case, the article 10 is created by the computer machine 14 in a Cartesian coordinate system, and the data file 18 creates a file of three-dimensional coordinates in the Cartesian coordinate system. Seed 32 is at the origin of the coordinate system.

FIG. 5 shows another embodiment of an apparatus for orienting granules according to predetermined three-dimensional coordinates for producing a three-dimensional article. In FIG. 5, an arcuate support 80 is provided over a 180 ° arc. The arcuate support 80 is rotatable about an axis 82 with 360 movements about the seed 32. The work head 84 is slidably carried on the arcuate track 86 of the arcuate support 80. The work head 84 can be moved by any suitable conventional servo control mechanism 88,
The servo mechanism 88 is controlled by the machine controller 16. In this case, only one machine head has 32 seeds.
It is necessary to stack and manufacture three-dimensional articles. The rotation of the support 80 is controlled by a suitable servo 90 controlled by the machine tensioning machine controller 16. The working head 84 emits a beam of energy that propels the particles toward the coordinates where the particles impact and adhere to each other, as described above.

FIG. 6 illustrates three machine heads 92, 94 and 96 in a Cartesian coordinate system for ejecting granules with yet another apparatus similar to the apparatus and method of FIGS. 4 and 5. Where the intersecting energy beams are X, Y,
It is used to place the granules at the Z coordinate. The servos 98, 100 and 102 work heads 92, 94 and according to a three-dimensional coordinate file (X, Y, Z) indicating the article to be designed.
96 respectively.

Above, 3 corresponding to the three-dimensional design of the article being manufactured
Although different mechanical devices have been described for directing particles to dimensional coordinates, it should be understood that other methods for controlling the orientation of particles can be utilized. For example, it is known in the art of ink ejection printing to control drop direction and final destination by using charged particles that are electrostatically reflected to a desired point or coordinate. Any particle-oriented principle carried out in these techniques is compatible with the methods and objectives described above, and one of ordinary skill in the art will readily apply this principle after being taught the method apparatus of the present invention. It is contemplated that this can be done. U.S. Pat. No. 4,400,705 and U.S. Pat. No. 4,408,211 disclose ink ejection devices and methods and devices for directing ink drops to a desired point.

Regardless of the electronics / machine and coordinate system used, it is desirable that the distance of the working head from each target coordinate point be kept uniform so that the particles impact each other with uniform force at the coordinate points.

By doing this, the distortion of the shape of the three-dimensional design is prevented and reduced. This can be done by programming this function into a program of the machine controller, as will be apparent to those skilled in computer programming.

[Brief description of drawings]

FIG. 1 is a schematic diagram showing computer-aided design of a three-dimensional article and automatic duplication of the article in a three-dimensional tangible shape. 2A-2C show the steps of replicating a three-dimensional object in polar coordinates according to the method and apparatus of the present invention. FIG. 3 is a perspective view showing another embodiment of the present invention. FIG. 4 is a plan view of the apparatus and method of FIG. 3 for automatic duplication of a three-dimensional article designed with the aid of a computer machine in accordance with the present invention. FIG. 5 is a perspective view showing another coordinate system and method and apparatus for automatically replicating a three-dimensional object designed with the aid of a computer machine. FIG. 6 is a perspective view showing another apparatus and method for automatically reproducing a three-dimensional object designed by a computer machine according to the present invention.

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Claims (22)

[Claims] 1. A method for designing an article (10) in two dimensions and then replicating the article in three dimensions, comprising a three-dimensional coordinate data file (18) showing the three-dimensional design of the article in a coordinate system. ) In a computer machine (14), in a controlled environment (40), in a controlled environment (40) a seed (32) that serves as a starting point in a coordinate system, and a source of collective particles. Giving, directing the particles (42, 44) from the source to the three-dimensional coordinates of the article in the coordinate system, arranging the particles (42, 44) in the coordinates, and the particles (42, 44) in the coordinates Seeds combined with each other (32)
A computer-aided manufacturing method comprising the steps of forming a three-dimensional article (34) around the. 2. A method according to claim 1 including pushing the collective particles toward the coordinates of the coordinate system to direct the particles to the coordinates. 3. The method of claim 1 including attracting the collective particles toward the coordinates and placing the particles at the coordinates. 4. Controlling the impact force of the collective particles such that the particles collide with each other with a uniform force in coordinates for the purpose of controlled mutual adhesion and low design distortion.
The method according to claim 1. 5. The method of claim 1 including utilizing electromagnetic force to direct the collective particles toward the coordinates. 6. A method according to claim 1 including utilizing magnetic force to direct the collective particles towards the coordinates. 7. A method according to claim 1 including providing a controlled charge energy beam (50, 52, 54) for directing the collective particles towards the coordinates of a coordinate system. 8. Crossing a pair of energy beams at intersections corresponding to three-dimensional coordinates, and utilizing the forces created by the intersecting beams at the intersections to position and combine particles at the coordinates. The method of claim 1 including. 9. A movable work head (24, 26; 58, 60, 62; 92,
94, 96), providing a programmed controller (16) for controlling the movement and position of the servo mechanism and the working head, data for controlling the working head in response to coordinate information. Transferring coordinate information from the file (18) to the programmed controller (16), the work head to the directional energy beam (50, 52, 54)
To direct the movement of the collective particles (42, 44) in the coordinate system, and to control the servo mechanism to position the working head according to the coordinate information, and design the collective particles in the coordinate system. The method of claim 1 including directing to the three-dimensional coordinates of. 10. Providing at least one additional working head, each emitting an energy beam, intersecting the beam with coordinates in a three-dimensional coordinate system, placing particles at the coordinates, and intersecting coordinates. 10. The method of claim 9 including positioning and bonding particles at the coordinates of the intersections by the force generated by the intersecting beams at. 11. A method according to claim 1, characterized in that the collective particles (42, 44) are a ceramic material and the controlled environment (40) is a closed environment heated or cooled to a desired temperature. The method according to item 1. 12. Method according to claim 1, characterized in that the collective particles are a plastic material and the controlled environment (40) is an ionizing atmosphere. 13. A method according to claim 1, characterized in that the collective particles (42, 44) are a slurry material with a high water content and the controlled environment (40) is a subzero environment. Method. 14. A uniform distance between the working head and the coordinates when the particles are directed to their respective coordinates such that the particles collide with each other with uniform forces in the coordinates to reduce distortion of the shape of the three-dimensional design. A method as claimed in claim 1 including maintaining. 15. A means for reproducing a tangible three-dimensional article from a data file (18) created by a computer machine for designing the article (10), said means comprising a three-dimensional coordinate system and a room. Data file (18) having three-dimensional coordinate information corresponding to the design of the article (10) in the space, control environment (40), tangible seeds (32) serving as the origin of the three-dimensional coordinate system, control environment (40) Means for locating the seed (32) in the coordinate system at the origin of the coordinate system, source of collective particles, directional means for directing collective particles (42, 44) from the source to the coordinates of the coordinate system in the controlled environment, directional means And a control means for controlling the three-dimensional article (34) around the seed (32) by combining the collective particles (42, 44) at the coordinate, and controlling the data corresponding to the coordinate information of the data file (18). A computer characterized by comprising Aided manufacturing equipment. 16. The directing means comprises an ejection head (58, 60, 62) for ejecting and directing a drop of collective particles to the coordinates of a coordinate system in the controlled environment (40). The device according to claim 15. 17. The directional means comprises a pair of machining heads each emitting a controlled energy beam, and the energy beams intersect each other at intersections corresponding to the coordinates, so that the collective particles are coordinated. Device according to claim 15, characterized in that it is arranged with respect to the coordinate system, such that it is arranged. 18. The directional means comprises at least one working head (24,26; 58,60,62; 92,94,96) which emits a controlled energy beam which directs the collective particles into coordinates. And servo means (20,22; 64,66,68; 98,100,102)
Is provided for moving the machining head, and programmed controller means (16) controls the servo means corresponding to the coordinate information of the data file (18) to direct the collective particles to the three-dimensional coordinates. Device according to claim 15, characterized in that it is arranged to move and position the working head accordingly. 19. A servo means is controlled to maintain a uniform distance between the machining head and a target coordinate, thereby causing the particles to collide with each other with a uniform force in coordinates due to low design distortion. Device according to claim 18, characterized in that it comprises means for moving the working head towards and away from the coordinates. 20. A directivity means having a polar coordinate system and for directing collective particles has a polar surface (30) of the polar coordinate system.
First directional ejection head (2
A second directional ejection head (24) having a 6), carried away from the pole face (30) for directing the energy beam towards the pole face (30), and a servo Device according to claim 15, characterized in that means (22, 20) are provided for controlling the movement of said first and second ejection heads. 21. The supporting means (80), wherein the directional means has an arc shape.
And means for rotating the arcuate support (80) with 360 degrees of freedom and an ejection carried by the arcuate support (80) movable with 180 degrees of freedom to emit an energy beam. Device according to claim 15, characterized in that it has a head (84). 22. A chamber having a closed chamber, wherein directional means is carried in the closed chamber to emit a plurality of energy beams, and a source of collective particles is contained within the chamber. A seed (32) is placed in the chamber, and means are provided for controlling the directional beam, crossed to correspond to the coordinates at the desired intersection and attract the particles at the intersection and coordinate the particles. 16. Device according to claim 15, characterized in that it is connected by