Method for manufacturing laminated shaped object

Abstract

In the internal shaping process of the internal shaping portion of the frame portion, the following processing is performed: a preliminary measurement processing, in which the shape of the base of the stacked weld bead layer is measured; a deviation calculation processing, in which the measured contour of the base is produced based on the measured value of the measured base shape, and the planned contour of the base is obtained based on the stacking plan, and the deviation of the measured contour from the planned contour is calculated; and a preliminary correction processing, in which, when the weld bead layer is stacked on the base, the welding conditions of the weld bead constituting the weld bead layer in the stacking plan are corrected to reduce the deviation.

Description

Technical Field

[0001] The present invention relates to a method for manufacturing a laminated object. Background Art

[0002] In recent years, demand for 3D printers as a production tool has increased, with research and development focused on their practical application in the aircraft industry, among other areas, particularly in the application of metal materials. 3D printers using metal materials use a heat source such as a laser or arc to melt metal powder or wire, then layer the molten metal to create an object.

[0003] As a technique for shaping a shaped object by welding, Patent Document 1 discloses shaping an outline portion and shaping a filled portion surrounded by the outline portion using different welding conditions.

[0004] In addition, Patent Document 2 describes the following method: when welding iron columns for construction, a laser sensor is used to measure the shape of the deposited weld bead in real time, and welding conditions are selected from a database based on the measured weld bead shape to adjust the target position of the welding torch, welding current, welding voltage, etc.

[0005] Furthermore, Non-Patent Document 1 describes a method for adjusting the height and width of a formed deposited weld bead by controlling the welding voltage and welding speed based on the weld bead shape measured by a laser sensor during lamination molding using a molten wire.

[0006] Prior art literature

[0007] Patent Literature

[0008] Patent Document 1: Japanese Patent Application Publication No. 2018-187679

[0009] Patent Document 2: Japanese Patent Application Laid-Open No. 9-182962

[0010] Non-patent literature

[0011] Non-patent literature 1: Han Q., Li Y., Zhang G. (2018) Online Control of DepositedGeometry of Multi-layer Multi-bead Structure for Wire and Arc AdditiveManufacturing. In: Chen S., Zhang Y., Feng Z. (eds) Transactions on Intelligent Welding Manufacturing. Transactions on Intelligent Welding Manufacturing. Springer, Singapore Summary of the Invention

[0012] Problems to be solved by the invention

[0013] Furthermore, in a shaping method in which an outer frame consisting of a contour line portion is previously shaped and the interior is filled, as in Patent Document 1, it is considered that, as in Patent Document 2 and Non-Patent Document 1, the shape of the formed deposited weld bead is measured using a shape sensor while feedback control is performed on the weld bead formation position or welding conditions in the next step.

[0014] However, in this case, when the shape sensor measures the shape near the outer frame formed by the contour line portion, the outer frame may become an obstruction, making it impossible to use the shape sensor to measure the shape of the area within the outer frame where the weld bead is stacked. This makes it difficult to form the weld bead while performing real-time corrections through feedback control, and the stacking accuracy of the weld bead may be reduced.

[0015] Therefore, an object of the present invention is to provide a method for manufacturing a laminated shaped object that can laminate weld beads with high precision based on measurement results obtained by a shape sensor to manufacture a high-quality laminated shaped object.

[0016] Solutions to Problems

[0017] The present invention is constituted by the following structure.

[0018] A method for manufacturing a laminated shaped object, wherein the shaped object is formed by laminating weld beads formed by melting and solidifying a filler material, wherein:

[0019] The manufacturing method of the stacked shaped object comprises:

[0020] a stacking planning step of creating a stacking plan for shaping the object by stacking the deposited weld beads based on a target shape of the object; and

[0021] a shaping step in which the deposited weld beads are repeatedly stacked based on the stacking plan;

[0022] The molding process comprises:

[0023] a frame forming step, in which the frame is formed using the deposited weld bead; and

[0024] an internal shaping step in which a plurality of weld beads are formed in parallel within the frame portion to shape an internal shaping portion formed by stacking weld bead layers composed of the weld beads;

[0025] In the internal molding process, the following processing is performed:

[0026] a preliminary measurement process in which the shape of a base on which the deposited weld bead layer is stacked is measured;

[0027] a deviation amount calculation process in which a measured contour of the base is created based on the measured value of the base shape, a planned contour of the base is obtained based on the stacking plan, and a deviation amount of the measured contour from the planned contour is calculated; and

[0028] A preliminary correction process is performed in which, when laminating the deposited weld bead layer on the base, welding conditions of the deposited weld bead constituting the deposited weld bead layer in the lamination plan are corrected so as to reduce the deviation amount.

[0029] Effects of the Invention

[0030] According to the present invention, it is possible to laminate weld beads with high precision based on the measurement results obtained by the shape sensor, thereby manufacturing a high-quality laminated shaped object. BRIEF DESCRIPTION OF THE DRAWINGS

[0031] Figure 1 This is a schematic diagram of the overall structure of a manufacturing system for manufacturing a laminated structure using a manufacturing method according to an embodiment of the present invention.

[0032] Figure 2 This is a schematic side view illustrating a shape sensor.

[0033] Figure 3 1 is a schematic cross-sectional view of a stacked structure showing an example of the stacked structure.

[0034] Figure 4 This is a schematic cross-sectional view of a laminated structure in which a first weld bead layer is formed within a frame.

[0035] Figure 5It is a schematic cross-sectional view showing the positional relationship between the frame portion and the shape sensor.

[0036] Figure 6 This is a schematic perspective view of a stacked shaped object in the process of being manufactured, explaining a preliminary shape measurement process.

[0037] Figure 7 This is a schematic perspective view of a stacked shaped object in the process of being manufactured, illustrating an application example of the preliminary shape measurement process.

[0038] Figure 8 is a diagram showing a stacked object in the process of being formed based on actual measurement values, and Figure 8 (A) is a schematic cross-sectional view of the stacked structure. Figure 8 (B) is a schematic diagram showing the measured profile.

[0039] Figure 9 is a diagram showing a stacked object in the process of being formed based on a stacking plan. Figure 9 (A) is a schematic cross-sectional view of the stacked structure. Figure 9 (B) is a schematic diagram showing the outline of the plan.

[0040] Figure 10 This is a diagram illustrating the pre-calibration process. Figure 10 (A) is a composite diagram of the measured profile and the planned profile. Figure 10 (B) is a diagram showing the cross-sectional shape of the weld bead constituting the second weld bead layer corrected in consideration of the deviation amount.

[0041] Figure 11 This is a schematic cross-sectional view of a stacked object that has been shaped after undergoing preliminary calibration. DETAILED DESCRIPTION

[0042] Hereinafter, embodiments of the present invention will be described in detail with reference to the accompanying drawings.

[0043] Figure 1 It is a structural diagram of a manufacturing system for manufacturing the laminated structure of the present invention.

[0044] The manufacturing system 100 of the laminated object of this structure includes a laminated molding device 11 , a controller 13 for comprehensively controlling the laminated molding device 11 , and a power supply device 15 .

[0045] The stacking molding apparatus 11 includes a welding robot 19 having a welding torch 17 mounted on its distal shaft and a filler material supply unit 21 for supplying a filler material (welding torch) M to the welding torch 17. A shape sensor 23 is mounted on the distal shaft of the welding robot 19 together with the welding torch 17.

[0046] The welding robot 19 is a multi-joint robot, and a welding torch 17 attached to a distal shaft of a robot arm continuously supports a filler material M. The position and posture of the welding torch 17 can be arbitrarily set three-dimensionally within the range of the robot arm's freedom.

[0047] The welding torch 17 has a shield nozzle (not shown) from which shielding gas is supplied. The arc welding method may be a consumable electrode method such as covered arc welding or carbon dioxide gas arc welding, or a non-consumable electrode method such as TIG welding or plasma arc welding, and the method is appropriately selected depending on the laminated object to be produced.

[0048] For example, in the case of a consumable electrode type, a contact tip is disposed within the shielded nozzle, and filler material M, which supplies a melting current, is held by the contact tip. While holding the filler material M, the welding torch 17 generates an arc from the tip of the filler material M under a shielding gas atmosphere. The filler material M is fed from the filler material supply unit 21 to the welding torch 17 via a not-shown extraction mechanism attached to a robotic arm or the like. As the continuously fed filler material M melts and solidifies while the welding torch 17 is moved, a linear weld bead B, representing the molten and solidified filler material M, is formed on the base plate 51, and a layered object W is formed from this weld bead B.

[0049] like Figure 2 As shown, a shape sensor 23 is provided in parallel with the welding torch 17 and moves along with the welding torch 17. This shape sensor 23 measures the shape of the portion that serves as the base when forming the weld bead B. For example, a laser sensor that acquires height data from reflected light from an irradiated laser beam is used as this shape sensor 23. A camera for three-dimensional shape measurement may also be used as the shape sensor 23.

[0050] The controller 13 includes a CAD / CAM unit 31 , a trajectory calculation unit 33 , a storage unit 35 , a deviation amount calculation unit 37 , a correction unit 39 , and a control unit 41 connecting these units.

[0051] The CAD / CAM unit 31 inputs or creates shape data (CAD data, etc.) of the laminated object W to be produced.

[0052] The trajectory calculation unit 33 decomposes the shape model of the three-dimensional shape data into a plurality of weld bead layers corresponding to the heights of the weld bead B. Furthermore, a stacking plan is created that determines the trajectory of the welding torch 17 for forming the weld bead B and the heating conditions for forming the weld bead B (including welding conditions for obtaining the weld bead width, weld bead stacking height, etc.) for each layer of the decomposed shape model.

[0053] The deviation calculation unit 37 compares the stacking plan generated by the trajectory calculation unit 33 with the actual values ​​measured by the shape sensor 23. It also calculates the deviation between the shape of the base portion when forming the weld bead B based on the stacking plan and the shape based on the actual values.

[0054] The correction unit 39 calibrates the welding conditions based on the stacking plan when forming the weld bead B based on the deviation amount calculated by the deviation amount calculation unit 37 .

[0055] The control unit 41 executes the driver program stored in the storage unit 35 to drive the welding robot 19 and the power supply 15 . Specifically, the welding robot 19 moves the welding torch 17 according to the command from the controller 13 and melts the filler material M with the arc to form a weld bead B on the base plate 51 .

[0056] It should be noted that the base plate 51 is made of a metal plate such as a steel plate, and is generally larger than the bottom surface (bottommost surface) of the stacked object W. The base plate 51 is not limited to a plate shape, and may be a base in other shapes such as a block or a rod.

[0057] All commercially available welding torches can be used as the filler material M. For example, welding wires specified in JIS Z 3312 solid wires for MAG welding and MIG welding for mild steel, high-tensile steel, and low-temperature steel, and JIS Z 3313 flux-cored wires for arc welding for mild steel, high-tensile steel, and low-temperature steel can be used.

[0058] Next, an example of a laminated object formed by the production method of this embodiment will be described.

[0059] Figure 3 1 is a schematic cross-sectional view of a stacked object W showing an example of the stacked object W. FIG.

[0060] like Figure 3 As shown, the stacked shaped object W includes a frame portion 53 formed by laminating deposited weld beads B1 on a base plate 51. Furthermore, the stacked shaped object W includes an internal shaped portion 55 formed by deposited weld beads B2 within the frame portion 53. The internal shaped portion 55 is formed by laminating deposited weld bead layers BL composed of deposited weld beads B2.

[0061] Next, the case of forming the laminated object W will be described.

[0062] (Frame molding process)

[0063] The welding robot 19 drives the welding torch 17 of the stacking molding device 11 while moving the filler material M. Then, a deposited weld bead B1 composed of the melted filler material M is supplied and stacked on the base plate 51, thereby molding a frame portion 53 having a generally rectangular shape in plan view, which is formed by the deposited weld bead B1 stacked on the base plate 51.

[0064] (Internal molding process)

[0065] A weld bead B2 is formed inside the frame 53. This weld bead B2 is formed along the width of the frame 53. This creates a weld bead layer BL composed of multiple weld beads B2 formed in parallel within the frame 53. This weld bead layer BL is then stacked inside the frame 53 to form the internal molded portion 55.

[0066] According to this manufacturing method, after the frame portion 53 is formed, the internally formed portion 55 is formed inside the frame portion 53 . Therefore, the internally formed portion 55 can be efficiently formed using the weld bead B2 having a large cross-sectional area.

[0067] However, if Figure 4 As shown, when deposited weld bead layers BL composed of deposited weld beads B2 are stacked to form the internal molding portion 55 within the frame portion 53, for example, valley-shaped depressions may form at the boundaries between the individual deposited weld beads B2 that constitute the first deposited weld bead layer BL, resulting in a concave-convex top surface of the first deposited weld bead layer BL. Specifically, when forming the second deposited weld bead layer BL that becomes the upper layer, the top surface shape of the first deposited weld bead layer BL, which serves as the base for this deposited weld bead layer BL, may deviate from the shape based on the stacking plan. In this case, even if the second deposited weld bead layer BL is formed according to the stacking plan within the first deposited weld bead layer BL, the stacked molded object W will not be molded into the target shape.

[0068] In this case, when forming the weld bead B2 constituting the internal molding portion 55, the shape of the base is measured in real time, and the measurement result is fed back to correct the welding conditions of the weld bead B2. Figure 5 As shown, when the shape of the substrate is measured by the shape sensor 23 near the frame 53 , the frame 53 becomes an obstruction, making it impossible to measure the shape by the shape sensor 23 and difficult to perform real-time feedback control.

[0069] Therefore, in this embodiment, in order to shape the target-shaped laminated object W, the following preliminary shape measurement processing, deviation calculation processing, and preliminary correction processing are performed when forming the weld bead layer BL. Here, the case of forming the second weld bead layer BL is described as an example.

[0070] Figure 6This is a schematic perspective view of a stacked object W in the process of being manufactured, for explaining a preliminary shape measurement process. Figure 7 This is a schematic perspective view of a stacked shaped object W in the process of being manufactured, explaining an application example of the preliminary shape measurement process. Figure 8 : is a diagram showing a stacked object W in the process of being formed based on actual measurement values. Figure 8 (A) is a schematic cross-sectional view of the stacked structure W. Figure 8 (B) is a schematic diagram showing the measured profile RP. Figure 9 FIG. 1 is a diagram showing a stacked object W in the process of being formed based on a stacking plan. Figure 9 (A) is a schematic cross-sectional view of the stacked structure W. Figure 9 (B) is a schematic diagram showing the plan profile PP. Figure 10 This is a diagram illustrating the pre-calibration process. Figure 10 (A) is a schematic diagram showing the result of synthesizing the measured profile RP and the planned profile PP. Figure 10 (B) is a schematic diagram showing the cross-sectional shape of the weld bead B2 constituting the second weld bead layer BL corrected in consideration of the deviation amount. Figure 11 It is a schematic cross-sectional view of a stacked object W formed by performing a preliminary calibration process.

[0071] (Preliminary shape measurement processing)

[0072] After the frame 53 is formed in the frame forming step, the first weld bead layer BL is formed in the internal forming step (see Figure 4 ) and before shaping the second layer of deposited weld bead BL, as Figure 6 As shown in the figure, a preliminary shape measurement process is performed to measure the shape of the stacked object in the middle of shaping. In this preliminary shape measurement process, the welding robot 19 is driven to move the shape sensor 23 arranged in parallel with the welding torch 17 along the predetermined shaping position of the second layer of the deposited weld layer BL. In addition, the shape is measured along the forming direction of the deposited weld B2 using the shape sensor 23. It should be noted that the shape measurement performed by the shape sensor 23 can also be performed in a direction different from the direction along the forming direction of the deposited weld B2. At this time, the shape sensor 23 interferes with the frame portion 53 that has been shaped, so it is sometimes difficult to perform shape measurement of the inner edge portion of the frame portion 53. In such a case, as Figure 7 As shown, the shape sensor 23 is tilted relatively inwardly relative to the frame 53, so that the measurement range of the shape sensor 23 is directed toward the inside of the frame 53. This prevents the measurement performed by the shape sensor 23 from being blocked by the frame 53 itself, and allows for good measurement of the shape inside the frame 53.

[0073] Figure 8(A) shows the cross-sectional shape of the object in the process of being shaped based on the actual measurement value of the shape sensor 23. In the cross-sectional shape based on the actual measurement value, Figure 8 The region S1 in (A) becomes the cross-sectional shape of the weld bead layer BL to be laminated as the second layer. Figure 8 As shown in (B), the measured profile RP of the object in the process of being shaped is produced.

[0074] (Deviation calculation process)

[0075] The deviation amount calculation unit 37 compares the measured contour of the object in process of formation created based on the measured value of the shape sensor 23 with the planned contour of the object in process of formation based on the layer plan, and calculates the deviation amount of the measured contour from the planned contour.

[0076] Figure 9 (A) shows the cross-sectional shape of the object in the process of being formed based on the stacking plan.

[0077] In the cross-sectional shape based on this stacking plan, Figure 9 The area S2 in (A) becomes the cross-sectional shape of the weld bead layer BL to be laminated as the second layer. Figure 9 As shown in (B), a planned outline PP of the object in the process of being shaped is produced.

[0078] like Figure 10 As shown in (A), the deviation amount calculation unit 37 compares the measured profile RP with the planned profile PP and estimates the deviation area S3 ( Figure 10 The hatched portion in (A) of FIG. 3 is obtained by calculating the amount of deviation as the cross-sectional area of ​​the deviation region S3. It should be noted that the deviation amount calculation unit 37 obtains the deviation position together with the calculation of the deviation amount.

[0079] (Pre-calibration processing)

[0080] Next, the correction unit 39 performs a preliminary correction process for correcting the welding conditions for forming the deposited weld bead B2 of the second deposited weld bead layer BL based on the deviation amount and deviation position between the planned profile PP and the measured profile RP. Figure 10As shown in (B) of FIG. , the correction unit 39 takes into account the amount and position of deviation between the planned profile PP and the measured profile RP to correct the welding conditions for the deposited weld bead B2 so that the surface of the second deposited weld bead layer BL is formed in accordance with the stackup plan. In this example, the cross-sectional area of ​​the first deposited weld bead layer BL actually formed is smaller than that of the first deposited weld bead layer BL planned based on the stackup plan. In this case, the welding conditions are corrected to increase the cross-sectional area of ​​the deposited weld bead B2 forming the second deposited weld bead layer BL. It should be noted that if the cross-sectional area of ​​the first deposited weld bead layer BL actually formed is larger than that of the first deposited weld bead layer BL planned based on the stackup plan, the welding conditions are corrected to decrease the cross-sectional area of ​​the deposited weld bead B2 forming the second deposited weld bead layer BL. This correction of the welding conditions to increase or decrease the cross-sectional area of ​​the deposited weld bead B2 is performed by adjusting the welding speed, the feed rate of the filler material M, or the welding current when forming the deposited weld bead B2. Note that, for this correction, it is preferable to search for and set welding conditions having a cross-sectional area of ​​a deposited weld bead that covers the excess or deficiency from, for example, a database of welding conditions accumulated in advance.

[0081] Afterwards, if Figure 11 As shown, a weld bead B2 is formed on the first weld bead layer BL under the corrected welding conditions, thereby shaping the second weld bead layer BL. This compensates for the deviation between the planned profile PP and the measured profile RP, and the top surface of the second weld bead layer BL, formed by the weld bead B2 formed under the corrected welding conditions, approximates the shape based on the stacking plan.

[0082] As described above, according to the method for manufacturing a laminated object of this embodiment, a frame portion 53 is formed and an internal portion 55 is formed within the frame portion 53. Therefore, for example, the internal portion 55 can be efficiently formed using a deposited weld bead B2 having a large cross-sectional area. Thus, in the method for manufacturing a laminated object W in which the internal portion 55 is formed within the frame portion 53, the shape of the base of the laminated weld bead layer BL is measured to create a measured profile RP. A planned profile PP of the base is calculated based on the layup plan, and the deviation of the measured profile RP from the planned profile PP is calculated. Furthermore, when the weld bead layer BL is laminated on the base within the frame portion 53, the welding conditions of the deposited weld bead B2 constituting the weld bead layer BL, as specified in the layup plan, are corrected to reduce the deviation. Therefore, even if the shape of the base within the frame portion 53 deviates from the planned profile PP calculated based on the layup plan, the weld bead layer BL, consisting of the deposited weld bead B2 laminated on the base, can be made to approximate the shape of the layup plan. Thus, even if the presence of the frame 53 makes it difficult to form the deposited bead B2 while measuring the base shape in real time and performing feedback control, the internal shaping portion 55 can be well shaped in accordance with the stacking plan.

[0083] Furthermore, since the shape sensor 23 for measuring the base shape is provided in parallel with the welding torch 17, which moves based on the stacking plan, the trajectory of the welding torch 17 based on the stacking plan can be used for the measurement operation performed by the shape sensor 23. This makes it possible to easily measure the base shape using the shape sensor 23 without creating a trajectory program for moving the shape sensor 23.

[0084] In addition, even when the shape sensor 23 is arranged in parallel with the welding torch 17, by measuring the shape by tilting the shape sensor 23 relatively inward relative to the frame 53, it is possible to suppress interference of the shape sensor 23 with the frame 53 and well measure the shape of the part near the inner side of the frame 53.

[0085] It should be noted that during the internal shaping process of the internal shaping section 55, for example, at a central position away from the frame 53 where shape measurement is not obstructed by the frame 53, the welding conditions for forming the deposited weld bead B2 can be corrected in real time based on the shape of the base. Specifically, the following real-time correction process can be performed: the shape of the base is measured using the shape sensor 23 provided in parallel with the welding torch 17, and the welding conditions of the deposited weld bead B2 based on the stacking plan are corrected in real time based on the measured base shape while forming the deposited weld bead B2 using the welding torch 17.

[0086] In this way, in the internal molding process, real-time correction processing is performed at a position where shape measurement is not hindered by the frame 53 together with the pre-correction processing, so that the internal molding portion 55 in the frame 53 can be molded well and more efficiently.

[0087] Furthermore, in the preliminary measurement process, the inner side of the frame portion 53, including the frame portion 53 where real-time shape measurement and feedback control are difficult, is measured in advance along the frame portion 53. Therefore, compared to the case where the shape of the entire interior of the frame portion 53 is measured in advance, the shape of a specific portion of the base can be efficiently measured and preliminary correction processing can be performed.

[0088] It should be noted that when three or more weld bead layers BL are stacked within the frame 53, it is preferable to perform preliminary shape measurement, deviation calculation, and preliminary correction when shaping the third and subsequent weld bead layers BL. Alternatively, when shaping the first weld bead layer BL, the shape of the base plate 51 serving as the foundation for the first weld bead layer BL may be measured, and deviation calculation and preliminary correction may be performed.

[0089] Thus, the present invention is not limited to the above-mentioned embodiments, and the combination of the various structures of the embodiments and the changes and applications made by those skilled in the art based on the description in the specification and known technologies are also intended by the present invention and included in the scope of protection requested.

[0090] As described above, the following matters are disclosed in this specification.

[0091] (1) A method for manufacturing a laminated shaped object, wherein the shaped object is formed by laminating weld beads formed by melting and solidifying a filler material, wherein:

[0092] The manufacturing method of the stacked shaped object comprises:

[0093] a stacking planning step of creating a stacking plan for shaping the object by stacking the deposited weld beads based on a target shape of the object; and

[0094] a shaping step in which the deposited weld beads are repeatedly stacked based on the stacking plan;

[0095] The molding process comprises:

[0096] a frame forming step, in which the frame is formed using the deposited weld bead; and

[0097] an internal shaping step in which a plurality of weld beads are formed in parallel within the frame portion to shape an internal shaping portion formed by stacking weld bead layers composed of the weld beads;

[0098] In the internal molding process, the following processing is performed:

[0099] a preliminary measurement process in which the shape of a base on which the deposited weld bead layer is stacked is measured;

[0100] a deviation amount calculation process in which a measured contour of the base is created based on the measured value of the base shape, a planned contour of the base is obtained based on the stacking plan, and a deviation amount of the measured contour from the planned contour is calculated; and

[0101] A preliminary correction process is performed in which, when laminating the deposited weld bead layer on the base, welding conditions of the deposited weld bead constituting the deposited weld bead layer in the lamination plan are corrected so as to reduce the deviation amount.

[0102] According to the method for manufacturing a laminated object with this structure, a frame is formed and an internal portion is formed within the frame. Therefore, for example, the internal portion can be efficiently formed using a weld bead with a larger cross-sectional area. Thus, in the method for manufacturing a laminated object in which the internal portion is formed within the frame, the shape of the base on which the weld bead layers are stacked is measured to create a measured contour. A planned contour of the base is then calculated based on a stacking plan, and the deviation of the measured contour from the planned contour is calculated. Furthermore, when the weld bead layers are stacked on the base within the frame, the welding conditions of the weld bead layers in the stacking plan are corrected to reduce the deviation. Therefore, even if the shape of the base within the frame deviates from the planned contour calculated based on the stacking plan, the weld bead layers formed by the weld bead stacked on the base can be made to approximate the shape of the stacking plan. Thus, even if the presence of the frame makes it difficult to measure the base shape in real time and perform feedback control while forming the weld bead, the internal portion can still be well-formed to match the stacking plan.

[0103] (2) The method for producing a laminated structure according to (1), wherein:

[0104] In the preliminary measurement process, the shape of the base is measured using a shape sensor provided in parallel with a welding torch that melts the filler material to form the weld bead.

[0105] According to this method for manufacturing a laminated object, the shape sensor is placed in parallel with the welding torch that moves based on the lamination plan, so the trajectory of the welding torch based on the lamination plan can be used for measurement using the shape sensor. This makes it possible to easily measure the shape of the base using the shape sensor.

[0106] (3) The method for producing a laminated structure according to (2), wherein:

[0107] In the above-mentioned preliminary measurement process,

[0108] The shape sensor is tilted relatively inward with respect to the frame portion to measure the shape.

[0109] According to the method for manufacturing a laminated object of this structure, the shape sensor is tilted relatively inwardly relative to the frame to measure the shape. This can suppress interference of the shape sensor with the frame and satisfactorily measure the shape of the inner vicinity of the frame.

[0110] (4) The method for producing a laminated structure according to (2) or (3), wherein:

[0111] In the internal molding process,

[0112] A real-time correction process is performed to form the deposited weld bead while measuring the shape of the base using the shape sensor and correcting the welding conditions of the deposited weld bead based on the stacking plan in real time based on the measured shape of the base.

[0113] According to this method for manufacturing a laminated object, when forming an internally formed portion within a frame, real-time correction processing is performed alongside pre-calibration processing. Specifically, welding conditions for forming a deposited weld bead are corrected in real time based on the base's shape, at a location where shape measurement is not obstructed by the frame. This allows for superior and more efficient shaping of the internally formed portion within the frame.

[0114] (5) The method for producing a laminated structure according to any one of (1) to (4), wherein:

[0115] In the above-mentioned preliminary measurement process,

[0116] The inner side of the frame portion including the frame portion is measured along the frame portion.

[0117] According to the method for manufacturing a laminated object of this structure, the inner side of the frame, including the frame, is pre-measured along the frame. Specifically, by pre-measuring primarily the portion near the inner side of the frame, where real-time shape measurement and feedback control are difficult, the shape of a specific portion of the base can be more efficiently measured and pre-calibrated, compared to pre-measuring the shape of the entire interior of the frame.

[0118] This application is based on Japanese patent application (Japanese Patent Application No. 2020-138613) filed on August 19, 2020, the contents of which are incorporated herein by reference.

[0119] Description of Reference Numerals

[0120] 17 Welding Torch

[0121] 23 Shape Sensor

[0122] 53 frame

[0123] 55 Interior Design Department

[0124] B, B1, B2 deposited welds

[0125] BL deposited weld layer

[0126] M Filling material

[0127] PP Program Outline

[0128] RP measured profile

[0129] W stacked shapes.

Claims

1. A method for manufacturing a laminated shaped object, wherein the shaped object is formed by laminating weld beads formed by melting and solidifying a filler material, wherein: The manufacturing method of the stacked shaped object comprises: a stacking planning step of creating a stacking plan for shaping the object by stacking the deposited weld beads based on a target shape of the object; and a shaping step in which the deposited weld beads are repeatedly stacked based on the stacking plan; The molding process comprises: a frame forming step, in which the frame is formed using the deposited weld bead; and an internal shaping step in which a plurality of weld beads are formed in parallel within the frame portion to shape an internal shaping portion formed by stacking weld bead layers composed of the weld beads; In the internal molding process, the following processing is performed: a preliminary measurement process in which the shape of a base on which the deposited weld bead layer is stacked is measured; a deviation amount calculation process in which a measured contour of the base is created based on the measured value of the base shape, a planned contour of the base is obtained based on the stacking plan, and a deviation amount of the measured contour from the planned contour is calculated; and a pre-correction process in which, when laminating the deposited weld layer on the base, welding conditions of the deposited weld beads constituting the deposited weld layer in the lamination plan are corrected to reduce the amount of deviation; In the above-mentioned preliminary measurement process, The inner side of the frame portion including the frame portion is measured along the frame portion.

2. The method for manufacturing a laminated structure according to claim 1, wherein: In the preliminary measurement process, the shape of the base is measured using a shape sensor provided in parallel with a welding torch that melts the filler material to form the weld bead.

3. The method for manufacturing a laminated structure according to claim 2, wherein: In the above-mentioned preliminary measurement process, The shape sensor is tilted relatively inward with respect to the frame portion to measure the shape.

4. The method for producing a laminated structure according to claim 2 or 3, wherein: In the internal molding process, A real-time correction process is performed to form the deposited weld bead while measuring the shape of the base using the shape sensor and correcting the welding conditions of the deposited weld bead based on the stacking plan in real time based on the measured shape of the base.

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