Three-dimensional modeling device and calibration method for three-dimensional modeling nozzle

Abstract

This invention provides a three-dimensional modeling apparatus and a calibration method for a three-dimensional modeling nozzle, and provides a technique for measuring the positional offset of the nozzle in the modeling surface of the worktable in the three-dimensional modeling apparatus. The three-dimensional modeling apparatus includes: an ejection section having a nozzle; a worktable having a modeling surface on which modeling material is deposited; a position changing section for changing the relative position of the nozzle and the worktable; a control section for controlling the position changing section; and a measuring unit for measuring the difference between the nozzle and a reference position within the modeling surface based on a first position and a second position, wherein the first position is the position of the nozzle within the modeling surface assumed to be controlled by the control section via the position changing section, and the second position is the position of the nozzle within the modeling surface changed by the control section via the position changing section.

Description

Technical Field

[0001] This disclosure relates to a three-dimensional modeling apparatus and a calibration method for a nozzle used in three-dimensional modeling. Background Technology

[0002] Regarding three-dimensional modeling devices, Patent Document 1 discloses measuring the distance between the front end face of the nozzle and the modeling surface of the worktable for modeling three-dimensional objects, and adjusting this distance to a predetermined distance.

[0003] Patent Document 1: Japanese Patent Application Publication No. 2021-812

[0004] In Patent Document 1, the modeling accuracy of a three-dimensional object can be improved by adjusting the height of the nozzle relative to the worktable. However, for example, if the origin position of the nozzle is offset in the modeling surface of the worktable, material cannot be correctly deposited in the target area on the worktable. Therefore, a technique to measure the positional offset of the nozzle in the modeling surface of the worktable is desired. Summary of the Invention

[0005] According to a first aspect of this disclosure, a three-dimensional modeling apparatus is provided. The three-dimensional modeling apparatus includes: an ejection section having a nozzle; a worktable having a modeling surface on which modeling material is deposited; a position changing section for changing the relative position of the nozzle and the worktable; a control section for controlling the position changing section; and a measuring unit for measuring the difference between the nozzle and a reference position within the modeling surface based on a first position and a second position, wherein the first position is assumed to be the position of the nozzle within the modeling surface by the control section controlling the position changing section, and the second position is the position of the nozzle within the modeling surface changed by the control section controlling the position changing section.

[0006] According to a second aspect of this disclosure, a calibration method for a three-dimensional modeling nozzle in a three-dimensional modeling apparatus is provided. The three-dimensional modeling apparatus includes: an ejection section having a nozzle; a worktable having a modeling surface on which modeling material is deposited; a position changing section for changing the relative position of the nozzle and the worktable; and a control section for controlling the position changing section.

[0007] In the calibration method, the difference between the nozzle and the reference position within the shaping surface is measured based on a first position and a second position. The first position is the position of the nozzle within the shaping surface assumed by the control unit controlling the position changing unit, and the second position is the position of the nozzle within the shaping surface changed by the control unit controlling the position changing unit. Attached Figure Description

[0008] Figure 1 This is an explanatory diagram showing the general structure of the three-dimensional modeling device in the first embodiment.

[0009] Figure 2 It is a three-dimensional diagram showing the general structure of a flat screw.

[0010] Figure 3 This is a general top view showing the opposite part of the screw.

[0011] Figure 4 An explanatory diagram that schematically represents the appearance of a three-dimensional object.

[0012] Figure 5 It is a three-dimensional diagram showing the specific structure of the workbench.

[0013] Figure 6 It is a 3D view of a portion of the workbench.

[0014] Figure 7 yes Figure 6 Top view.

[0015] Figure 8 This is a flowchart of the calibration process.

[0016] Figure 9 This is an explanatory diagram showing the general structure of the three-dimensional modeling device in the second embodiment.

[0017] Figure 10 This is an explanatory diagram showing the general structure of the three-dimensional modeling device in the third embodiment.

[0018] Figure 11 This is a diagram illustrating other examples of scar formation in the third embodiment.

[0019] Explanation of reference numerals in the attached figures

[0020] 10, 10B, 10C…3D modeling device; 20…Material supply unit; 22…Connecting path; 30…Modeling material generation unit; 31…Screw housing; 32…Drive motor; 40…Flat screw; 42…Slot; 43…Raised section; 44…Material inlet; 46…Central section; 47…Upper surface; 48…Lower surface; 50…Screw opposite section; 52…Upper surface; 54…Guide groove; 56…Connecting hole; 58…Heater; 60, 60C…Ejection section; 61…Nozzle; 62…Ejection outlet; 63…Scar formation nozzle; 65…Flow path; 70…Flow rate adjustment unit; 74…First drive unit; 75…Suction unit; 76…Second drive unit; 101…Control unit; 102…Modeling… 110…Shaping section; 210…Workbench; 211…Shaping surface; 212…Workbench heater; 213…Protrusion; 214…Scratching component; 215…Support block; 216…Recess; 217, 218…Edge; 220…Support platform; 221…First stop; 222…Second stop; 223…Force application section; 224…Gutter; 230…Position changing section; 300…Measuring unit; 310…Detection section; 311…Camera; 312…Arm; 400…Correction section; 401…First adjusting screw; 402…Second adjusting screw; 601…First ejection section; 602…Second ejection section; 611…First nozzle; 612…Second nozzle. Detailed Implementation

[0021] A. First implementation method:

[0022] Figure 1 This is an explanatory diagram showing the general structure of the three-dimensional modeling device 10 in the first embodiment. Figure 1 The diagram shows arrows representing the mutually orthogonal X, Y, and Z directions. The X and Y directions are parallel to the horizontal plane, and the Z direction is vertically upward. These arrows representing the X, Y, and Z directions are also appropriately illustrated in other figures, such that the directions shown are consistent with... Figure 1 Correspondingly. In the following explanation, when the direction is specific, the direction indicated by the arrow in each diagram will be marked as "+", and the opposite direction will be marked as "-". Both positive and negative signs will be used in the direction markings. Hereinafter, the +Z direction will also be called "up", and the -Z direction will also be called "down".

[0023] The three-dimensional modeling device 10 includes a modeling section 110 that generates and sprays modeling material, a worktable 210 having a modeling surface 211 on which modeling material is piled, a position changing section 230 that changes the relative position of the nozzle 61 and the worktable 210, a control section 101 that controls the position changing section 230, and a detection section 310 that forms part of the measuring unit 300.

[0024] Under the control of the control unit 101, the molding unit 110 melts solid materials into a paste-like molding material and sprays it onto the worktable 210. Here, "melting" includes the concept of plasticization, which not only refers to the material exhibiting fluidity when heated to a temperature above its melting point, but also, in the case of materials with a glass transition point, the material softens when heated to a temperature above the glass transition point, thus exhibiting fluidity. The molding unit 110 includes a material supply unit 20 as a supply source of material before it is converted into molding material, a molding material generation unit 30 for converting material into molding material, and an ejection unit 60 for spraying out the molding material.

[0025] The material supply unit 20 supplies the raw material MR for generating the modeling material to the modeling material generation unit 30. The material supply unit 20 is, for example, constituted by a hopper for storing the raw material MR. The material supply unit 20 has a discharge port at its lower part. This discharge port is connected to the modeling material generation unit 30 via a connecting passage 22. The raw material MR is fed into the material supply unit 20 in the form of granules or powder. In this embodiment, granular ABS resin is used.

[0026] The molding material generating unit 30 melts the raw material MR supplied from the material supply unit 20 and generates a paste-like molding material exhibiting fluidity, which is then guided towards the ejection unit 60. The molding material generating unit 30 includes a screw housing 31, a drive motor 32, a flat screw 40, and a screw-opposing part 50. The flat screw 40 is also referred to as a rotor or scroll, and the screw-opposing part 50 is also referred to as a barrel.

[0027] Figure 2 This is a three-dimensional view showing the approximate structure of the lower surface 48 side of the flat screw 40. Figure 2 The flat screw 40 shown is for ease of technical understanding. Figure 1 The upper surface 47 and the lower surface 48 shown are in opposite positions in the vertical direction. Figure 3 This is a general top view showing the upper surface 52 side of the screw-opposite portion 50. The flat screw 40 has a generally cylindrical shape with a height smaller than its diameter along its central axis, i.e., the axial direction. The flat screw 40 is configured such that the rotation axis RX, which is its center of rotation, is parallel to the Z direction.

[0028] The flat screw 40 is housed within the screw housing 31. The upper surface 47 of the flat screw 40 is connected to the drive motor 32, and the flat screw 40 rotates within the screw housing 31 via the rotational driving force generated by the drive motor 32. The drive motor 32 is driven under the control of the control unit 101. It should be noted that the flat screw 40 can also be driven by the drive motor 32 via a reducer.

[0029] A vortex-shaped groove 42 is formed on the lower surface 48 of the flat screw 40, which intersects the rotation axis RX. The connecting passage 22 of the aforementioned material supply section 20 connects from the side of the flat screw 40 to this groove 42. Figure 2 As shown, in this embodiment, the groove 42 is formed into three sections by being separated by the protrusion 43. It should be noted that the number of grooves 42 is not limited to three; one or more may be used. The groove 42 is not limited to a vortex shape; it may also be a spiral shape or an involute curve shape, or it may be a shape that extends from the center outward in an arc.

[0030] The lower surface 48 of the flat screw 40 faces the upper surface 52 of the screw-opposite portion 50, forming a space between the groove 42 of the lower surface 48 of the flat screw 40 and the upper surface 52 of the screw-opposite portion 50. In the shaping section 110, this space between the flat screw 40 and the screw-opposite portion 50 extends from the material supply section 20 towards... Figure 2 The material inlet 44 shown supplies raw material MR.

[0031] In the screw-opposite portion 50, a heater 58 is embedded in the groove 42 of the rotating flat screw 40 to supply raw material MR. In the screw-opposite portion 50, a plurality of guide grooves 54 are formed, connected to the connecting hole 56 and extending outward in a vortex shape from the connecting hole 56. It should be noted that one end of the guide groove 54 may not be connected to the connecting hole 56. Alternatively, the guide groove 54 may be omitted.

[0032] The raw material MR supplied to the groove 42 of the flat screw 40 melts within the groove 42 and flows along the groove 42 due to the rotation of the flat screw 40, being guided as a molding material towards the central portion 46 of the flat screw 40. The flowing, paste-like molding material into the central portion 46 is set... Figure 3 The center of the screw-opposite portion 50 shown is supplied to the ejection portion 60 via the connecting hole 56. It should be noted that in the molding material, all the substances constituting the molding material may not melt. The molding material is transformed into a fluid state as a whole by melting at least a portion of the substances constituting the molding material.

[0033] The ejection section 60 includes: a nozzle 61 for ejecting 3D modeling material, a material flow path 65 disposed between the flat screw 40 and the nozzle 61, a flow rate adjustment section 70 for switching the flow path 65, and a suction section 75 for attracting and temporarily storing the modeling material. The nozzle 61 is connected to a communication hole 56 of the screw-opposite section 50 via the flow path 65. The nozzle 61 ejects the modeling material generated in the modeling material generation section 30 from the front ejection outlet 62 toward the worktable 210. A heater may also be disposed around the nozzle 61 to suppress the temperature drop of the modeling material ejected on the worktable 210.

[0034] The flow rate adjustment unit 70 changes the opening degree of the flow path 65 by rotating within it. In this embodiment, the flow rate adjustment unit 70 is configured as a butterfly valve. The flow rate adjustment unit 70 is driven by a first drive unit 74 under the control of the control unit 101. The first drive unit 74 is, for example, configured as a stepper motor. Using the first drive unit 74, the control unit 101 can adjust the flow rate of the molding material flowing into the nozzle 61 from the molding material generation unit 30, that is, the flow rate of the molding material ejected from the nozzle 61, by controlling the rotation angle of the butterfly valve. While adjusting the flow rate of the molding material, the flow rate adjustment unit 70 also controls the opening / closing of the outflow of the molding material.

[0035] The suction unit 75 continues in the flow path 65 between the flow adjustment unit 70 and the nozzle 62. When the molding material stops being ejected from the nozzle 61, the suction unit 75 temporarily attracts the molding material in the flow path 65, suppressing the phenomenon of the molding material hanging off the nozzle 62 like a drawn wire. In this embodiment, the suction unit 75 is constructed as a plunger. The suction unit 75 is driven by a second drive unit 76 under the control of the control unit 101. The second drive unit 76 is, for example, constructed of a stepper motor, a rack and pinion mechanism that converts the rotational force of the stepper motor into the translational motion of the plunger, etc.

[0036] For example, when the ejection of molding material from nozzle 61 stops, control unit 101 first controls flow adjustment unit 70 to shut off the flow of molding material, and then controls suction unit 75 to attract molding material. Then, when ejection of molding material from nozzle 61 resumes, control suction unit 75 to deliver the material attracted by suction unit 75, and then control flow adjustment unit 70 to resume the flow of molding material. In this way, by controlling flow adjustment unit 70 and suction unit 75, control unit 101 can improve the ejection responsiveness of molding material.

[0037] The worktable 210 is positioned opposite the nozzle 61's outlet 62. In the first embodiment, the modeling surface 211 of the worktable 210 opposite the nozzle 61's outlet 62 is positioned in the X and Y directions, i.e., parallel to the horizontal direction. During three-dimensional modeling, the three-dimensional modeling apparatus 10 shapes a three-dimensional object by ejecting a layer of modeling material from the ejection section 60 toward the modeling surface 211 of the worktable 210. The worktable 210 includes a worktable heater 212, which serves as a heating element. The worktable heater 212 prevents a rapid drop in temperature of the modeling material ejected onto the worktable 210.

[0038] The position changing unit 230 changes the relative position of the nozzle 61 and the worktable 210. In this embodiment, the position of the nozzle 61 is fixed, and the position changing unit 230 moves the worktable 210. The position changing unit 230 is composed of a three-axis positioner that moves the worktable 210 in the X, Y, and Z directions by the driving force of three motors. The position changing unit 230 changes the relative positional relationship between the nozzle 61 and the worktable 210 under the control of the control unit 101. In this specification, without special limitation, the movement of the nozzle 61 means that the nozzle 61 moves relative to the worktable 210.

[0039] It should be noted that in other embodiments, instead of moving the worktable 210 via the position changing unit 230, the position changing unit 230 can move the nozzle 61 relative to the worktable 210 while the worktable 210 remains in a fixed position. Alternatively, the position changing unit 230 can move the worktable 210 in the Z direction and the nozzle 61 in the X and Y directions, or it can move the worktable 210 in the X and Y directions and the nozzle 61 in the Z direction. These configurations also allow for changes in the relative positional relationship between the nozzle 61 and the worktable 210.

[0040] The detection unit 310 consists of a camera 311 mounted on the shaping surface 211 of the imaging worktable 210 and an arm 312 capable of supporting the movement of the camera 311. The detection unit 310 is controlled by a control unit 101. Based on instructions from the control unit 101, the detection unit 310 drives the arm 312 and moves the camera 311 to a position opposite the worktable 210. Then, the detection unit 310 uses the camera 311 to capture images of a designated area on the worktable 210. The captured images are transmitted to the control unit 101.

[0041] The control unit 101 is a control device that controls the overall movement of the 3D modeling apparatus 10. The control unit 101 is composed of a computer equipped with one or more processors, a storage device, and an input / output interface for inputting and outputting signals to and from the outside. The control unit 101 executes programs or commands read from the storage device through the processor, thus functioning as a modeling processing unit 102. It should be noted that the control unit 101 can also be implemented using a combination of multiple circuits.

[0042] The modeling processing unit 102 controls the modeling unit 110 and the position changing unit 230 to model the three-dimensional model based on the modeling data used to model the three-dimensional model.

[0043] The styling processing unit 102 generates layer data by slicing the shape of the 3D model into multiple layers based on 3D CAD data representing the shape of the 3D model. Then, for each layer contained in this layer data, styling data is generated that includes path information representing the movement path of the ejector 60, and ejection amount information representing the amount of styling material ejected in each movement path. The movement path of the ejector 60 is the path along which the nozzle 61 moves relative to the styling surface 211 of the worktable 210 while ejecting styling material.

[0044] The path information consists of multiple partial paths. Each partial path is a straight line represented by a start point and an end point. The ejection quantity information is established in correspondence with each partial path. In this embodiment, the ejection quantity represented by the ejection quantity information is the amount of material ejected per unit time within that partial path. It should be noted that in other embodiments, the total amount of material ejected within the entire partial path can also be used as the ejection quantity information to establish a correspondence with each partial path.

[0045] Figure 4 This is an explanatory diagram schematically showing the appearance of a three-dimensional modeling object shaped in the three-dimensional modeling apparatus 10. As described above, in the modeling material generation unit 30, solid raw material MR supplied to the groove 42 of a rotating flat screw 40 is melted to generate modeling material MM. The control unit 101 maintains the distance between the modeling surface 211 of the worktable 210 and the nozzle 61 while changing the position of the nozzle 61 relative to the worktable 210 along the direction of the modeling surface 211, and ejects the modeling material MM from the nozzle 61. The modeling material MM ejected from the nozzle 61 continuously accumulates in the moving direction of the nozzle 61. By scanning with the nozzle 61, a linear portion LP is modeled as a modeling portion extending linearly along the scanning path of the nozzle 61. During the modeling of the three-dimensional object, the control unit 101 controls the worktable heater 212 to raise the temperature of the worktable 210 to a predetermined temperature.

[0046] The control unit 101 repeatedly scans the nozzle 61 to form a layer ML. After forming a layer ML, the control unit 101 moves the position of the nozzle 61 relative to the worktable 210 in the Z direction. Then, a three-dimensional object is shaped by stacking layers ML on the formed layer ML.

[0047] The control unit 101 may temporarily interrupt the ejection of molding material from the nozzle 61, for example, when moving in the Z direction towards the nozzle 61 after completing one layer of ML, or when multiple independent molding areas exist in each layer. In this case, the flow path 65 is blocked by the flow adjustment unit 70 to stop the ejection of molding material MM from the nozzle outlet 62. After changing the position of the nozzle 61, the control unit 101 restarts the accumulation of molding material MM from the changed position of the nozzle 61 by opening the flow path 65 by the flow adjustment unit 70.

[0048] Figure 5 This is a perspective view showing the specific structure of the worktable 210. When viewed in the -Z direction, the worktable 210 is roughly rectangular and rests on the support platform 220. A [missing information - likely a device or structure] is arranged between the worktable 210 and the support platform 220. Figure 1 The workbench heater 212 shown.

[0049] In this embodiment, straight grooves 224 formed along the Y direction are equally spaced in the X direction on the molding surface 211 of the worktable 210. These grooves 224 are provided to create an anchoring effect in the molding material ejected from the molding surface 211. It should be noted that in other embodiments, such grooves 224 may not be provided.

[0050] A trapezoidal protrusion 213 protruding in the +X direction is provided at the end of the worktable 210. The support platform 220 includes a first stop 221 and a second stop 222. The first stop 221 is used to position the edge of the worktable 210 in the +Y direction, and the second stop 222 is used to position the edge of the worktable 210 in the -X direction. Furthermore, the support platform 220 includes a force-applying part 223, which has a spring for pressing the protrusion 213 of the worktable 210 in both the -X and +Y directions. The worktable 210 is positioned and fixed on the support platform 220 by these first stop 221, second stop 222, and force-applying part 223.

[0051] Figure 6 This is a 3D view of a portion of the enlarged worktable 210. Figure 7 yes Figure 6 A top view. A plate-shaped scratch-forming component 214 is disposed in the corner of the worktable 210 in both the -X and -Y directions. The scratch-forming component 214 is composed of... Figure 1The detection unit 310 and the measurement unit 300 shown are configured. The scratch forming member 214 is detachably fixed to a support block 215 for fixing the scratch forming member 214 to the worktable 210. The support block 215 is detachably fixed relative to the worktable 210 at the corners in the -X and -Y directions. With this configuration, the scratch forming member 214 is provided at a predetermined position on the worktable 210.

[0052] A recess 216, incorporating a scratch-forming member 214, is formed on the upper surface of the support block 215. When viewed in the -Z direction, the -X direction edge 217 of the recess 216 coincides with the -X direction edge of the molding surface 211. Furthermore, when viewed in the -Z direction, the -Y direction edge 218 of the recess 216 coincides with the -Y direction edge of the molding surface 211. Figure 7 As shown, the intersection of the extended edges 217 in the -X direction and 218 in the -Y direction of the recess 216 is at the reference position of the modeling surface 211, i.e., the origin (0, 0).

[0053] The scar-forming component 214 is through Figure 6 The scratch-forming nozzle 63 shown is a component for forming scratches. The scratch-forming nozzle 63 does not have an outlet; the portion corresponding to the outlet has a sharp shape in the -Z direction. That is, the scratch-forming nozzle 63 is a component that simulates the nozzle 61, and is not a component for ejecting molding material. The scratch-forming nozzle 63 is mounted on the ejection section 60 in a manner that covers the nozzle 61. Specifically, the scratch-forming nozzle 63 can be attached and detached relative to the ejection section 60 by screwing a threaded groove formed on the inner surface of the scratch-forming nozzle 63 into the threaded teeth formed around the nozzle 61. With this configuration, the position of the nozzle 61 in the molding surface 211 coincides with the position of the scratch-forming nozzle 63. It should be noted that in other embodiments, the nozzle 61 and the scratch-forming nozzle 63 can also be interchangeably mounted on the ejection section 60.

[0054] The hardness of the scratch-forming nozzle 63 is higher than that of the scratch-forming component 214. In this embodiment, the hardness is referred to as Vickers hardness. The scratch-forming nozzle 63 is formed, for example, from carbon steel or steel-carbon-chromium bearing steel, using a mechanical structure. In contrast, the scratch-forming component 214 is formed, for example, from aluminum. Therefore, by moving the control position changing unit 230 and the ejection portion 60 on which the scratch-forming nozzle 63 is mounted relative to each other in the -Z direction and pressing it against the scratch-forming component 214, the control unit 101 forms dot-shaped scratches SK in the scratch-forming component 214 through the sharp tip of the scratch-forming nozzle 63.

[0055] The control unit 101, together with the support block 215, uses the camera 311 provided in the detection unit 310 to photograph the scratch SK. Through image analysis, it measures the distance from the edge of the recess 216 formed in the support block 215 in the -X direction to the scratch SK and the distance from the edge of the recess 216 in the -Y direction to the scratch SK. Therefore, it is possible to determine the position of the scratch SK relative to the origin of the shaping surface 211, that is, the position of the nozzle 61 relative to the origin of the shaping surface 211.

[0056] Figure 8 This is a flowchart of the calibration process performed by the control unit 101. This process is performed at a predetermined time, such as before the 3D modeling device 10 leaves the factory or after the worktable 210 is replaced. It should be noted that a scratch-forming nozzle 63 is installed in the ejection unit 60 before the calibration process begins.

[0057] In step S10, the control unit 101 controls the stage heater 212 to raise the temperature of the stage 210 to the temperature at which the three-dimensional model was created. This allows calibration to be performed in the same environment as the actual three-dimensional modeling process.

[0058] In step S20, the control unit 101 uses the scratch-forming nozzle 63 to perform a scratch-forming process in the scratch-forming member 214. In this scratch-forming process, the control unit 101 first determines a first position, assumed to be located within the molding surface 211 of the nozzle 61, via the control position change unit 230. The first position is, for example, 10 mm in the +X direction and 10 mm in the +Y direction from the origin of the molding surface 211. This first position is determined as a position where a scratch can indeed be formed in the scratch-forming member 214. Next, the control unit 101 moves the position of the scratch-forming nozzle 63 within the molding surface 211 to the first position via the control position change unit 230. Then, the control unit 101 moves the scratch-forming nozzle 63 relative to the first position in the -Z direction via the control position change unit 230, forming a scratch in the scratch-forming member 214. The action achieved through this scratch-forming process is called the scratch-forming action.

[0059] In step S30, the control unit 101 performs a scratch measurement process to determine the location of the scratch. In this scratch measurement process, the control unit 101 controls the detection unit 310 to move the camera 311 on the shaping surface 211. Then, the camera 311 captures an image including the scratch-forming component 214 and the support block 215. The control unit 101 obtains this image from the camera 311 and determines the location of the scratch by analyzing the image. The determined location of the scratch is called the second position. The second position is the position of the nozzle 61 within the shaping surface 211 that the control unit 101 changes by controlling the position changing unit 230. That is, the first position described above is an assumed position of the nozzle 61 in the shaping surface 211, while the second position is the actual position of the nozzle 61 in the shaping surface 211. If no positional shift occurs in the nozzle 61, the second position is consistent with the first position.

[0060] In step S40, the control unit 101 performs a correction value calculation process. In this process, the control unit 101 calculates the difference between the first and second positions in the X direction and the difference between the first and second positions in the Y direction. For example, if the coordinates (X, Y) of the first position are (10mm, 10mm) and the coordinates (X, Y) of the second position are (12mm, 9mm), then the difference between the nozzle 61 and the reference position within the molding surface 211, i.e., the origin, becomes (+2mm, -1mm). Then, the control unit 101 calculates a correction value (-2mm, +1mm) to eliminate this difference.

[0061] The control unit 101 non-volatilely stores the correction values ​​calculated through the calibration process described above in its own storage device. When performing 3D modeling via the modeling processing unit 102, the control unit 101 corrects the coordinates of the nozzle 61 from the command value indicating the position of the nozzle 61 relative to the position change unit 230 using the correction values ​​stored in the storage device. This allows for 3D modeling while simultaneously correcting the position of the nozzle 61. It should be noted that the control unit 101 can also correct the path information included in the modeling data used in 3D modeling based on the correction values. This allows for 3D modeling while simultaneously correcting the position of the nozzle 61.

[0062] The three-dimensional modeling apparatus 10 described above includes a measuring unit 300 for measuring the positional offset of the nozzle 61. In this embodiment, using the measuring unit 300, the difference between the nozzle 61 and the reference position within the modeling surface 211 can be measured based on a first position of the control unit 101 within the modeling surface 211 of the nozzle 61, assumed to be located by the control position changing unit 230, and a second position of the nozzle 61 within the modeling surface 211 changed by the control unit 101 by the control position changing unit 230. In other words, the positional offset of the nozzle 61 from the origin of the modeling surface 211 can be measured.

[0063] Furthermore, the measuring unit 300 used in this embodiment includes a detection unit 310 with a camera 311 for detecting the second position. Therefore, the actual position of the nozzle 61, i.e., the second position, can be easily measured.

[0064] Furthermore, in this embodiment, the position change unit 230 is controlled to perform three-dimensional modeling based on the measurement results from the measurement unit 300. Therefore, the position change unit 230 can be controlled to model a three-dimensional object in a manner that corrects the positional offset of the nozzle 61. As a result, for example, modeling material with excellent precision can be ejected from the groove 224 formed in the modeling surface 211.

[0065] Furthermore, the three-dimensional modeling apparatus 10 of this embodiment includes a scratch forming member 214 disposed at a predetermined position on the worktable 210. The control unit 101, through the control position changing unit 230, causes the scratch forming nozzle 63 to move to a first position and contact the tip of the scratch forming nozzle 63 with the scratch forming member 214, thereby performing a scratch forming operation to form a scratch SK for measuring a second position. Therefore, the position of the scratch SK formed by the scratch forming member 214 can be used as the assumed position of the nozzle 61, corresponding to the actual position of the nozzle 61 at the first position, i.e., the second position, for measurement.

[0066] Furthermore, in this embodiment, the ejection section 60 is configured to be able to attach and detach a scratch-forming nozzle 63 that does not have an ejection outlet. Therefore, it is possible to suppress the deterioration of the nozzle 61 due to the scratch-forming action on the scratch-forming member 214.

[0067] Furthermore, in this embodiment, the hardness of the scratch-forming nozzle 63 is higher than that of the scratch-forming component 214. Therefore, the deterioration of the scratch-forming nozzle 63 can be suppressed by the scratch-forming operation.

[0068] Furthermore, in this embodiment, the scratch formation process is performed during the calibration process after the worktable 210 is heated by the worktable heater 212. Therefore, the positional offset of the nozzle 61 can be measured considering the thermal expansion of the worktable 210 during the modeling of the three-dimensional object.

[0069] It should be noted that in the first embodiment, the location of the scratch is determined using the camera 311 provided with the detection unit 310. In contrast, the location of the scratch can also be measured by the user using a measuring instrument such as a vernier caliper, and the measured value is input to the control unit 101 using a prescribed input device.

[0070] B. Second implementation method:

[0071] Figure 9This is an explanatory diagram showing the general configuration of the three-dimensional modeling device 10B in the second embodiment. In the first embodiment described above, a correction value is calculated to correct the position of the nozzle 61 based on the measurement results using the measurement unit 300, and the movement of the nozzle 61 is controlled using this correction value. In contrast, the three-dimensional modeling device 10B of the second embodiment has a correction unit 400 that physically corrects the position of the nozzle 61 based on the measurement results using the measurement unit 300.

[0072] like Figure 9 As shown, the calibration unit 400 includes a first adjusting screw 401 and a second adjusting screw 402. The first adjusting screw 401 moves the ejection portion 60, including the nozzle 61, in both the +X and -X directions, while the second adjusting screw 402 moves the ejection portion 60 in both the +Y and -Y directions. For example, a user uses the measuring unit 300 to measure the difference between a first position and a second position, and by operating the first adjusting screw 401 and the second adjusting screw 402 in a manner that makes the difference zero, the position of the nozzle 61 is physically corrected. This allows for the correction of the relative position of the nozzle 61 and the worktable 210.

[0073] It should be noted that in the second embodiment, the correction unit 400 is configured to physically correct the position of the nozzle 61. In contrast, the correction unit 400 may also be configured to physically correct the installation position of the position changing unit 230.

[0074] C. Third implementation method:

[0075] Figure 10 This is an explanatory diagram showing the general configuration of the three-dimensional modeling device 10C in the third embodiment. In the first embodiment described above, the ejection section 60 has one nozzle 61. In contrast, the ejection section 60C in the third embodiment has two nozzles serving as nozzles for three-dimensional modeling. Specifically, the ejection section 60C includes a first ejection section 601 and a second ejection section 602. The first ejection section 601 has a first nozzle 611. Then, the second ejection section 602 has a second nozzle 612. Different materials are ejected from the first nozzle 611 and the second nozzle 612, for example. For example, one material is the modeling material, and the other material is the support material. In addition, the different materials may be materials with different colors or materials with different textures.

[0076] In the calibration process of the third embodiment, the control unit 101 forms scratches on the scratch forming member 214 using the nozzles provided on each of the ejection units 60. For example, a scratch is formed at the coordinate (10mm, 10mm) position of the scratch forming nozzle 63 mounted on the first nozzle 611, and at the coordinate (15mm, 15mm) position of the scratch forming nozzle 63 mounted on the second nozzle 612. Then, the positions of these scratches are measured respectively. For example, if the position of the scratch formed by the scratch forming nozzle 63 mounted on the first nozzle 611 is (10mm, 10mm) and the position of the scratch forming nozzle 63 mounted on the second nozzle 612 is (16mm, 15mm), there are two nozzles offset by 1mm in the X direction. Therefore, when the control unit 101 uses the second nozzle 612 for shaping, it can eliminate this offset by controlling the position change unit 230, thereby eliminating the positional offset between the nozzles and performing three-dimensional shaping. It should be noted that the positional misalignment between the nozzles can also be eliminated, as in the second embodiment, by physically adjusting the position of at least one of the first ejection portion 601 and the second ejection portion 602.

[0077] Figure 11 This diagram illustrates other examples of scar formation in the third embodiment. In the third embodiment, for example... Figure 11 As shown, an L-shaped scratch SK1 is formed by the scratch-forming nozzle 63 mounted on the first nozzle 611, and an L-shaped scratch SK2 can also be formed at a position away from the scratch SK1 formed by the scratch-forming nozzle 63 mounted on the second nozzle 612. The positional offset between the nozzles can then be determined by measuring the interval between these scratches SK1 and SK2 in the X and Y directions.

[0078] D. Other implementation methods:

[0079] (D1) In the above embodiment, for example, a camera 311 is movably arranged between the nozzle 61 and the worktable 210. By photographing the nozzle 61 from below with the camera 311, the position of the nozzle 61 can be directly determined without using the scratch forming member 214 or the scratch forming nozzle 63. In addition, the position of the nozzle 61 is not limited to the camera 311, and various optical sensors such as shape measuring sensors using two-dimensional lasers can be used to determine the position of the nozzle 61.

[0080] (D2) In the above embodiment, a scratch is formed in the scratch forming member 214 by a scratch forming nozzle 63, and the position of the scratch is determined as the position of the nozzle 61. In contrast, for example, if the molding material is sprayed out from the nozzle 61 in a dotted or linear pattern on the molding surface 211 of the worktable 210, the positional offset of the nozzle 61 can also be determined by measuring the position of the molding material on the molding surface 211.

[0081] (D3) In the above embodiment, a scratch is formed on the scratch forming member 214 by the scratch forming nozzle 63. Conversely, a scratch can also be formed on the scratch forming member 214 by the ejection nozzle 61. For example, the control unit 101 can form a scratch on the scratch forming member 214 by pressing the nozzle 61 against the scratch forming member 214 to move the nozzle 61 relative to the scratch forming member 214 in the -Z direction. It should be noted that when a scratch is formed by the nozzle 61, it is preferable that the hardness of the nozzle 61 is higher than the hardness of the scratch forming member 214.

[0082] (D4) In the above embodiment, the scratch forming component 214 is mounted on the worktable 210 via a support block 215. However, the support block 215 is not necessary, and the scratch forming component 214 can also be directly mounted on the worktable 210.

[0083] (D5) In the above embodiment, the worktable 210 includes a worktable heater 212. However, the worktable 210 may also not include a worktable heater 212. In this case, it is omitted. Figure 8 Heating of stage 210 during the calibration process shown.

[0084] (D6) In the above embodiment, the control unit 101 performs a scratch-forming operation after the worktable 210 is heated during the calibration process. Conversely, the control unit 101 can also perform a scratch-forming operation both before and after heating the worktable 210 during the calibration process. Then, the control unit 101 uses the detection unit 310 to measure the positions of the two scratches formed before and after heating and calculates the differences between these positions. Therefore, the control unit 101 can measure not only the positional offset of the nozzle 61, but also the amount of thermal expansion of the worktable 210 in the planar direction.

[0085] E. Other methods:

[0086] This disclosure is not limited to the embodiments described above, and various configurations can be implemented without departing from its intent. For example, technical features corresponding to the technical features in the embodiments described below can be appropriately replaced or combined to solve some or all of the above-described technical problems, or to achieve some or all of the above-described effects. In addition, those technical features that must be described in this specification can be appropriately deleted.

[0087] (1) According to a first aspect of this disclosure, a three-dimensional modeling apparatus is provided. This three-dimensional modeling apparatus includes: an ejection section having a nozzle; a worktable having a modeling surface on which modeling material is deposited; a position changing section for changing the relative position of the nozzle and the worktable; a control section for controlling the position changing section; and a measuring unit for measuring the difference between the nozzle and a reference position within the modeling surface based on a first position and a second position, wherein the first position is assumed to be a position of the nozzle within the modeling surface by the control section controlling the position changing section, and the second position is the position of the nozzle within the modeling surface changed by the control section controlling the position changing section. In this way, the positional offset of the nozzle within the modeling surface of the worktable can be measured.

[0088] (2) Alternatively, in the above-described manner, the measuring unit may have a detection unit for detecting the second position. In this manner, the second position can be easily measured.

[0089] (3) Alternatively, in the above-described manner, the control unit may control the position changing unit based on the measurement results obtained using the measuring unit. In this manner, the position changing unit can be controlled to correct for nozzle positional offset, and a three-dimensional object can be shaped.

[0090] (4) Alternatively, the above method may include a correction unit that corrects the relative position of the nozzle and the worktable based on the measurement results obtained using the measuring unit. In this case, the nozzle position can be corrected based on the difference between the measured nozzle position and the reference position.

[0091] (5) Alternatively, in the above-described manner, the measuring unit may have a scratch-forming component disposed at a predetermined position on the worktable. The control unit controls the position changing unit to move the nozzle relative to the scratch-forming component at the first position, thereby contacting the tip of the nozzle and performing a scratch-forming operation to form a scratch for measuring the second position. In this manner, the position of the scratch formed on the scratch-forming component can be measured as the second position.

[0092] (6) In the above-described manner, the ejection portion may also be configured as the nozzle to be able to attach and detach a scratch-forming nozzle without an ejection outlet. In this manner, it is possible to suppress nozzle deterioration due to the scratch-forming action on the scratch-forming component.

[0093] (7) Alternatively, in the above-described manner, the hardness of the scratch-forming nozzle may be higher than the hardness of the scratch-forming component. In this manner, deterioration of the scratch-forming nozzle can be suppressed.

[0094] (8) Alternatively, in the above-described manner, the control unit may include a heating unit for heating the worktable, and the scratch-forming operation may be performed after the worktable is heated by the heating unit. In this manner, the positional deviation of the nozzle can be measured taking into account the thermal expansion of the worktable.

[0095] (9) Alternatively, in the above-described manner, the control unit may perform the scratch-forming action before heating the worktable, in addition to heating it via the heating unit. In this manner, the thermal expansion of the worktable can be easily measured.

[0096] (10) In the above-described manner, the ejection section may include a first ejection section and a second ejection section, and the control unit may perform a second measurement action to bring the front ends of the nozzles of the first ejection section and the nozzles of the second ejection section into contact with the scratch-forming component. In this manner, the positional offset between the two nozzles can be measured.

[0097] (11) According to a second aspect of this disclosure, a calibration method for a three-dimensional modeling nozzle in a three-dimensional modeling apparatus is provided. The three-dimensional modeling apparatus includes: an ejection section having a nozzle; a worktable having a modeling surface on which modeling material is deposited; a position changing section for changing the relative position of the nozzle and the worktable; and a control section for controlling the position changing section.

[0098] In the calibration method, the difference between the nozzle and the reference position within the shaping surface is measured based on a first position and a second position. The first position is the position of the nozzle within the shaping surface assumed by the control unit controlling the position changing unit, and the second position is the position of the nozzle within the shaping surface changed by the control unit controlling the position changing unit.

Claims

1. A three-dimensional modeling device, characterized in that, have: An ejection section with a nozzle; A worktable with a surface for stacking modeling materials; A position-changing unit that alters the relative position of the nozzle and the worktable; Control unit that controls the position change unit; as well as A measuring unit is used to measure the difference between the nozzle and a reference position within the shaping surface based on a first position and a second position. The first position is the position of the nozzle within the shaping surface assumed by the control unit controlling the position changing unit, and the second position is the position of the nozzle within the shaping surface changed by the control unit controlling the position changing unit. The measuring unit has a scratch-forming component disposed at a predetermined position on the worktable. The control unit controls the position changing unit to move the nozzle to the first position, so that the tip of the nozzle contacts the scar forming member, thereby performing a scar forming operation to form a scar for measuring the second position.

2. The three-dimensional modeling device according to claim 1, characterized in that, The measuring unit has a detection section for detecting the second position.

3. The three-dimensional modeling device according to claim 1 or 2, characterized in that, The control unit controls the position change unit based on the measurement results obtained using the measurement unit.

4. The three-dimensional modeling device according to claim 1 or 2, characterized in that, It has a correction unit that corrects the relative position of the nozzle and the worktable based on the measurement results using the measuring unit.

5. The three-dimensional modeling device according to claim 1, characterized in that, The ejection portion is configured as the nozzle to be able to attach and detach a scratch-forming nozzle that does not have an ejection outlet.

6. The three-dimensional modeling device according to claim 5, characterized in that, The hardness of the nozzle for forming the scratch is higher than that of the component for forming the scratch.

7. The three-dimensional modeling device according to any one of claims 1, 5, and 6, characterized in that, The three-dimensional modeling device includes a heating unit for heating the worktable. The control unit performs the scratch formation action after heating the worktable through the heating unit.

8. The three-dimensional modeling device according to claim 7, characterized in that, The control unit performs the scratch-forming action not only after heating the worktable via the heating unit but also before heating the worktable.

9. The three-dimensional modeling device according to claim 1, characterized in that, The ejection section includes a first ejection section and a second ejection section. During the scar-forming operation, the control unit causes the front ends of the nozzles of the first ejection unit and the second ejection unit to contact the scar-forming component.

10. A calibration method, characterized in that, This refers to a calibration method for a nozzle used in a 3D modeling device, wherein the 3D modeling device has: An ejection section with a nozzle; A worktable with a surface for stacking modeling materials; A position changing unit that alters the relative position of the nozzle and the worktable; and The control unit that controls the position change unit. The difference between the nozzle and the reference position within the shaping surface is determined based on a first position and a second position. The first position is the position of the nozzle within the shaping surface assumed by the control unit controlling the position changing unit. The second position is the position of the nozzle within the shaping surface changed by the control unit controlling the position changing unit. The three-dimensional modeling device has a scratch-forming component disposed at a predetermined position on the worktable. The control unit controls the position changing unit to move the nozzle to the first position, so that the tip of the nozzle contacts the scar forming member, thereby performing a scar forming operation to form a scar for measuring the second position.

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