Additive manufacturing apparatus and additive manufacturing method

Abstract

An additive manufacturing apparatus (100) has a build section (30) having a material supply section that supplies a material to a workpiece, a heat source output section that outputs a heat source that melts the material, and a drive section that moves the heat source and the material supply section, a weld bead being formed from the material that is melted by use of the heat source, an operation amount adjustment section that adjusts a material supply amount of the material supply section or a heat source output of the heat source output section based on a shape error of the weld bead, and an operation amount readjustment section (33) that sets a range of values of the material supply amount with respect to values of the heat source output, i.e., an appropriate range, at which the weld bead can be properly formed, and in a case where the values of the material supply amount after adjustment in the operation amount adjustment section deviate from the appropriate range with respect to the values of the heat source output, selects one of the material supply amount and the heat source output as an operation amount for which adjustment is prioritized, and readjusts the selected operation amount preferentially.

Description

Additional manufacturing apparatus and additional manufacturing method Technical Field

[0001] This invention relates to an attachment manufacturing apparatus and method for manufacturing 3D objects. Background Technology

[0002] Additive manufacturing (AM) is a known technique for creating 3D objects. One method within AM, Directed Energy Deposition (DED), involves a manufacturing apparatus supplying material to a designated location while simultaneously irradiating the material and the workpiece with a light beam, thereby forming weld beads. These weld beads are solidified deposits formed when molten material solidifies at the workpiece. The AM apparatus creates objects by sequentially stacking these weld beads.

[0003] In auxiliary manufacturing processes, errors relative to the target shape sometimes occur in the shape of the formed weld bead due to various reasons. Therefore, various methods have been proposed to reduce shape errors by controlling the auxiliary manufacturing apparatus. Patent Document 1 proposes a technique in which the amount of material supplied to the processing point is corrected based on the measurement results of the weld bead height to address shape errors that result in errors relative to the target height.

[0004] Patent Document 1: Japanese Patent No. 6765569 Summary of the Invention

[0005] In ancillary manufacturing processes, the amount of material that can be melted at the processing point is determined based on the output value of the heat source that melts the material. If the amount of material supplied to the processing point cannot be corrected, processing cannot continue if an appropriate amount of material cannot be melted. As described above, in the case of ancillary manufacturing processes, even if the operating quantity, which is the object of control, is corrected, the limitations for continuing processing may not always be met. Therefore, according to the prior art described in Patent Document 1 above, there is a problem that it is sometimes difficult to manufacture shapes with reduced errors.

[0006] The present invention was made in view of the above circumstances, and its object is to provide an additional manufacturing apparatus capable of producing shapes with reduced errors.

[0007] To solve the aforementioned problems and achieve the objective, the auxiliary manufacturing apparatus according to the present invention includes: a forming unit having a material supply unit that supplies material to a workpiece, a heat source output unit that outputs a heat source that melts the material, and a drive unit that moves the heat source and the material supply unit, thereby forming a weld bead from the material melted by using the heat source; an operation amount adjustment unit that adjusts the material supply amount of the material supply unit or the heat source output of the heat source output unit based on the shape error of the weld bead; and an operation amount readjustment unit that sets a range, i.e., an appropriate range, for the value of the material supply amount relative to the value of the heat source output when the weld bead can be appropriately formed, and when the value of the material supply amount relative to the value of the heat source output deviates from the appropriate range after adjustment in the operation amount adjustment unit, selects one of the material supply amount and the heat source output as the operation amount that prioritizes adjustment, and readjusts the selected operation amount preferentially.

[0008] The effects of the invention

[0009] The additional manufacturing apparatus involved in this invention has the effect of being able to manufacture shapes with reduced errors. Attached Figure Description

[0010] Figure 1 is a diagram showing an example of the additional manufacturing apparatus according to Embodiment 1.

[0011] Figure 2 is a diagram showing an example of the functional structure of the additional manufacturing apparatus involved in Embodiment 1.

[0012] Figure 3 is a first figure used to illustrate the relationship between laser output and material supply in the additional manufacturing apparatus according to Embodiment 1.

[0013] Figure 4 is a second figure used to illustrate the relationship between laser output and material supply in the additional manufacturing apparatus involved in Embodiment 1.

[0014] Figure 5 is the third figure used to illustrate the relationship between laser output and material supply in the additional manufacturing apparatus involved in Embodiment 1.

[0015] Figure 6 is a diagram illustrating an example of the relationship between the material supply and laser output obtained by positioning the front end of the wire in the appropriate position in the additional manufacturing apparatus according to Embodiment 1.

[0016] Figure 7 is a first figure for explaining the selection of the operation quantity that prioritizes adjustment implemented by the operation quantity readjustment unit of the additional manufacturing apparatus according to Embodiment 1.

[0017] Figure 8 is a second figure explaining the selection of the operation quantity that prioritizes adjustment implemented by the operation quantity readjustment unit of the additional manufacturing apparatus according to Embodiment 1.

[0018] Figure 9 is the third figure for explaining the selection of the operation quantity that prioritizes adjustment implemented by the operation quantity readjustment unit of the additional manufacturing apparatus according to Embodiment 1.

[0019] Figure 10 is a first figure for explaining the readjustment of the operating amount implemented by the operating amount readjustment unit of the additional manufacturing apparatus according to Embodiment 1.

[0020] Figure 11 is a second figure for explaining the readjustment of the operating amount implemented by the operating amount readjustment unit of the additional manufacturing apparatus according to Embodiment 1.

[0021] Figure 12 is a diagram illustrating the readjustment of the operating quantity when an allowable error amount is set in Embodiment 1.

[0022] Figure 13 is a flowchart illustrating an example of the processing sequence implemented by the operation quantity readjustment unit of the auxiliary manufacturing apparatus according to Embodiment 1.

[0023] Figure 14 is a diagram illustrating the selection of the operation quantity that prioritizes adjustment implemented by the operation quantity readjustment unit of the additional manufacturing apparatus according to Embodiment 2.

[0024] Figure 15 is a first figure for explaining the readjustment of the operating amount implemented by the operating amount readjustment unit of the additional manufacturing apparatus according to Embodiment 2.

[0025] Figure 16 is a second figure for explaining the readjustment of the operating amount implemented by the operating amount readjustment unit of the additional manufacturing apparatus according to Embodiment 2.

[0026] Figure 17 is a diagram illustrating the readjustment of the operating quantity when an allowable error amount is set in Embodiment 2.

[0027] Figure 18 is a flowchart illustrating an example of the processing sequence implemented by the operation quantity readjustment unit of the additional manufacturing apparatus according to Embodiment 2.

[0028] Figure 19 is a diagram illustrating the relationship between the allowable error in the additional manufacturing apparatus according to Embodiment 2 and the generation of defects in the product.

[0029] Figure 20 is a diagram showing an example of the functional structure of the additional manufacturing apparatus involved in Embodiment 3.

[0030] Figure 21 is a first figure used to illustrate the relationship between the correction of the processing point and the formation of the weld bead in the additional manufacturing apparatus according to Embodiment 3.

[0031] Figure 22 is a second figure used to illustrate the relationship between the correction of processing points and the formation of weld beads in the additional manufacturing apparatus according to Embodiment 3.

[0032] Figure 23 is a diagram illustrating the correction of the weld width in the additional manufacturing apparatus according to Embodiment 3.

[0033] Figure 24 is a diagram illustrating the correction amount calculated by the weld width correction amount calculation unit of the additional manufacturing apparatus according to Embodiment 3.

[0034] Figure 25 is a flowchart illustrating an example of the processing sequence implemented by the position correction unit, position correction amount adjustment unit, and weld width correction amount calculation unit of the auxiliary manufacturing apparatus according to Embodiment 3.

[0035] Figure 26 is a diagram showing an example of the structure of the control circuit involved in embodiments 1 to 3.

[0036] Figure 27 is a diagram showing an example of the structure of the dedicated hardware circuit involved in embodiments 1 to 3. Detailed Implementation

[0037] The additional manufacturing apparatus and additional manufacturing method involved in the embodiments will now be described in detail based on the accompanying drawings.

[0038] Implementation method 1.

[0039] Figure 1 is a diagram showing an example of the auxiliary manufacturing apparatus 100 according to Embodiment 1. The auxiliary manufacturing apparatus 100 is a DED (Dual Engagement Equipment) type auxiliary manufacturing apparatus. The auxiliary manufacturing apparatus 100 supplies material to the workpiece 19 and stacks weld beads 16 formed by melting the material using a light beam to manufacture a shaped object 17. The light beam is a heat source that melts the material, such as a laser beam L or an electron beam. The heat source is not limited to a light beam and can also be an electric arc. In Embodiment 1, the case where the heat source is a laser beam L is taken as an example. In addition, in Embodiment 1, the material is set to be a metal wire 14. The material is not limited to wire 14 and can also be powder.

[0040] The auxiliary manufacturing apparatus 100 supplies wire 14 to a designated position while irradiating the wire 14 and the workpiece 19 with a laser beam L, thereby forming a weld bead 16. The weld bead 16 is formed in a molten pool 15. The molten pool 15 is a storage area of ​​molten metal that appears when the workpiece 19 and the wire 14 are melted by the irradiation of the laser beam L.

[0041] On the substrate 18, a layer of weld beads 16 is formed by arranging multiple weld beads 16. By stacking the layers of weld beads 16, a deposit of weld beads 16, i.e., a shaped object 17, is formed. As described above, the auxiliary manufacturing apparatus 100 manufactures the shaped object 17 as a 3D shaped object by stacking the weld beads 16. The substrate 18 shown in FIG. 1 is a sheet material. The substrate 18 can also be an article other than a sheet material. The workpiece 19 is an object to which molten material is applied, comprising the substrate 18 and the shaped object 17 in the molding process. The shaped object 17 is formed on the substrate 18.

[0042] The X, Y, and Z axes are three mutually perpendicular axes. The X and Y axes are two horizontal axes. The Z axis is the vertical axis. In each of the X, Y, and Z axes, the direction indicated by the arrow is set to positive, and the opposite direction is set to negative. The positive Z direction is the vertical direction. Weld bead 16 is stacked in the positive Z direction.

[0043] The auxiliary manufacturing apparatus 100 includes a numerical control (NC) device 1, a laser oscillator 2, an axis drive device 3, a gas supply device 4, a material supply device 5, a analytical device 6, a camera 7, a processing head 8, a PC (Personal Computer) 10, and a worktable 21. A substrate 18 is fixed to the worktable 21. The laser oscillator 2, axis drive device 3, gas supply device 4, material supply device 5, processing head 8, and worktable 21 constitute a shaping section 30, which manufactures a shaped object 17 by layering weld beads 16 formed from material molten using a laser beam L.

[0044] The laser oscillator 2, serving as the beam source, outputs a laser beam L. The laser oscillator 2 is an example of a heat source output section. The laser beam L output by the laser oscillator 2 is transmitted within the optical fiber 20, which serves as the light transmission path, and is directed into the processing head 8. An optical system, such as a collimating optical system or a focusing optical system, is disposed inside the processing head 8. A diagram of the optical system is omitted. The laser oscillator 2, the optical fiber 20, and the processing head 8 constitute an irradiation section that directs the laser beam L toward the workpiece 19.

[0045] The processing head 8 is equipped with a beam nozzle through which a laser beam L emitted from the processing head 8 toward the processing point passes; and a gas nozzle 9 through which a protective gas G is sprayed toward the processing point. The central axis of the beam nozzle is aligned with the optical axis of the optical system. The central axis of the beam nozzle is also aligned with the Z-axis. The centerline of the laser beam L irradiating the workpiece 19 is aligned with the Z-axis. The laser beam L passes through the internal optical system of the processing head 8 and exits from the processing head 8 through the beam nozzle. The processing point is the location on the workpiece 19 irradiated by the laser beam L, which is the area where the attached wire 14 is applied. In the additional processing of the molten material, the additional manufacturing apparatus 100 moves the processing point along a moving path. The location of the processing point is the location where the heat source and material are supplied, and is located on the central axis of the beam nozzle.

[0046] The gas supply device 4 supplies protective gas G from a gas supply source to the gas nozzle 9. An example of a gas supply source is a gas cylinder. The gas supply source is connected to the gas nozzle 9 via piping. (Diagrams of the gas supply source and piping are omitted.) Based on gas supply commands from the NC device 1, the gas supply device 4 can adjust the flow rate of the protective gas G. The injection of the protective gas G reduces oxidation of the material and workpiece 19, and cools the shaped object 17. The protective gas G is preferably an inert gas such as argon.

[0047] The material supply device 5, acting as a material supply unit, supplies wire 14 toward the processing point. The material supply device 5 includes a material supply source 12 and a material supply nozzle 13. The material supply device 5 supplies the wire 14 drawn from the material supply source 12 to the processing point via the material supply nozzle 13. Figure 1 shows an example of a side supply method where the wire 14 is supplied from the material supply nozzle 13 positioned diagonally above the processing point. The material supply device 5 may also supply the wire 14 from a central position, rather than a side supply method, via the material supply nozzle 13 positioned directly above the processing point. The material supply device 5 can be operated by a servo motor, changing the supply speed of the wire 14 based on material supply commands from the NC device 1.

[0048] The axis drive unit 3 moves the machining head 8, material supply device 5, and measuring device 11 in the X, Y, and Z axes based on the movement speed command from the NC device 1. The positional relationship between the machining head 8, material supply device 5, and measuring device 11 is fixed. An example of the axis drive unit 3 is a servo motor that moves the machining head 8, material supply device 5, and measuring device 11 in the X-axis direction, a servo motor that moves the machining head 8, material supply device 5, and measuring device 11 in the Y-axis direction, and a servo motor that moves the machining head 8, material supply device 5, and measuring device 11 in the Z-axis direction. Illustrations of each servo motor are omitted. By actuating each servo motor, the auxiliary manufacturing device 100 is able to move the irradiation position of the laser beam L, the supply position of the wire 14, and the measurement position of the measuring device 11 to any position within the travel range of the machining head 8, material supply device 5, and measuring device 11.

[0049] Camera 7 is an imaging device that takes pictures of the area containing the processing points in the workpiece 19 from above. As an example, camera 7 acquires an image of the area containing the processing points and outputs the acquired image to the analysis device 6.

[0050] The measuring device 11 measures the height of the weld bead 16 formed in the molten pool 15 in the Z-axis direction, i.e., the weld bead height. As an example, the measuring device 11 is a laser displacement sensor. The measuring device 11 is positioned so that it can move in the X-axis, Y-axis, and Z-axis directions via the axis drive device 3. The measuring device 11 outputs the measurement result of the weld bead height to the analysis device 6.

[0051] The analysis device 6 analyzes the image input from the camera 7, thereby measuring the width of the weld bead 16 formed in the molten pool 15, i.e., the weld bead width. Furthermore, the analysis device 6 calculates the error in the width of the formed weld bead 16, i.e., the weld bead width error. The analysis device 6 calculates the difference between the measured weld bead width value and the target weld bead width value, thereby determining the weld bead width error. The analysis device 6 outputs the value of the weld bead width error, i.e., the weld bead width error quantity, to the NC device 1.

[0052] The analysis device 6 calculates the height error of the formed weld bead 16, i.e., the weld bead height error. The analysis device 6 calculates the difference between the weld bead height measured by the measuring device 11 and the target value of the weld bead height, thereby determining the weld bead height error. The analysis device 6 outputs the value of the weld bead height error, i.e., the weld bead height error quantity, to the NC device 1.

[0053] The NC device 1 is a control device that controls the entire auxiliary manufacturing apparatus 100. The NC device 1 controls the auxiliary manufacturing apparatus 100 according to the machining program and machining conditions. The machining program contains movement commands for moving the machining head 8 and the material supply device 5 along a pre-set path. The machining conditions include information necessary for the formation of the weld bead 16, such as the output of the laser beam L generated by the laser oscillator 2 (laser output), the speed at which the irradiation position of the laser beam L and the supply position of the wire 14 move (movement speed), the amount of wire 14 supplied by the material supply device 5 (material supply amount), and the flow rate of the shielding gas G (gas flow rate). Furthermore, in the following description, the laser output will be referred to as the heat source output. The material supply amount in the following description will also be referred to as the material supply speed.

[0054] The NC device 1 outputs position commands corresponding to the machining program to the axis drive device 3, thereby controlling the axis drive device 3 according to the machining program. The axis drive device 3 moves the machining head 8 and the material supply device 5 along a pre-set movement path according to the position commands.

[0055] The NC device 1 outputs a laser output command to the laser oscillator 2 according to the processing conditions, thereby controlling the laser oscillator 2. The laser oscillator 2 outputs a laser beam L according to the laser output command. The NC device 1 outputs a material supply command to the material supply device 5 according to the processing conditions, thereby controlling the material supply device 5. The material supply device 5 supplies wire 14 according to the material supply amount specified in the material supply command. The NC device 1 outputs a movement speed command to the axis drive device 3 according to the processing conditions. The axis drive device 3 moves the irradiation position of the laser beam L and the supply position of the wire 14 at the movement speed specified in the movement speed command. The NC device 1 outputs a gas supply command to the gas supply device 4 according to the processing conditions, thereby controlling the gas supply device 4. The gas supply device 4 supplies protective gas G at the gas flow rate specified in the gas supply command.

[0056] Values ​​of various parameters related to the control of the auxiliary manufacturing device 100 are input to the PC 10 by the user of the auxiliary manufacturing device 100. The PC 10 outputs the input information to the NC device 1. In addition, the PC 10 displays an operation screen for operating the auxiliary manufacturing device 100.

[0057] Furthermore, the NC device 1 and PC 10 shown in FIG1 are built into the auxiliary manufacturing apparatus 100. That is, the NC device 1 and PC 10 are constituent elements of the auxiliary manufacturing apparatus 100. At least one of the NC device 1 and PC 10 may also be an external device of the auxiliary manufacturing apparatus 100.

[0058] Next, a summary of the operation of the auxiliary manufacturing apparatus 100 will be described. After the substrate 18 is fixed on the worktable 21, the auxiliary manufacturing apparatus 100 operates the laser oscillator 2, the axis drive device 3, the gas supply device 4, and the material supply device 5 under control via the NC device 1. The auxiliary manufacturing apparatus 100 operates the laser oscillator 2, thereby irradiating the processing point with a laser beam L. The auxiliary manufacturing apparatus 100 operates the material supply device 5, thereby supplying wire 14 to the processing point. The auxiliary manufacturing apparatus 100 operates the gas supply device 4, thereby injecting protective gas G towards the processing point. The auxiliary manufacturing apparatus 100 operates the axis drive device 3, thereby moving the processing point along the movement path.

[0059] A molten pool 15 is formed on the workpiece 19 by irradiation with a laser beam L. The processing point moves as the molten pool 15 is formed, thereby forming a weld bead 16. By stacking the weld beads 16, a shape 17 is formed.

[0060] Next, the function of reducing the shape error of weld bead 16 will be explained. The auxiliary manufacturing apparatus 100 has a function for reducing the shape error of weld bead 16. FIG2 is a diagram showing an example of the functional structure of the auxiliary manufacturing apparatus 100 according to Embodiment 1. FIG2 shows an example of the functional structure related to the function of reducing the shape error of weld bead 16.

[0061] The NC device 1 includes a weld width correction control unit 31, a weld height correction control unit 32, and an operation amount readjustment unit 33. The weld width correction control unit 31 and the weld height correction control unit 32 function as operation amount adjustment units that adjust the material supply amount of the material supply device 5 or the heat source output of the laser oscillator 2 based on the shape error of the weld 16. In Embodiment 1, the weld width error and the weld height error are each shape errors of the weld 16.

[0062] The weld width error calculated by the analysis device 6 is input to the weld width correction control unit 31. Upon receiving the weld width error, the weld width correction control unit 31 adjusts the laser output indicated by the laser output command generated by the processing conditions based on the weld width error. The weld width correction control unit 31 controls the correction of the weld width by adjusting the laser output based on the weld width error. The weld width correction control unit 31 outputs the adjusted laser output value to the operation amount readjustment unit 33.

[0063] The weld height error calculated by the analysis device 6 is input to the weld height correction control unit 32. If the weld height error is input, the weld height correction control unit 32 adjusts the material supply amount indicated by the material supply command generated by the processing conditions based on the weld height error. The weld height correction control unit 32 controls the correction of the weld height by adjusting the material supply amount based on the weld height error. The weld height correction control unit 32 outputs the adjusted material supply amount to the operation amount readjustment unit 33.

[0064] PC 10 has a parameter input unit 34 for inputting various parameter values. These values ​​are input, for example, through user operation. One parameter value, namely the tolerance value, is input to the parameter input unit 34. In Embodiment 1, the tolerance value is the allowable weld height error. By inputting the tolerance value to the parameter input unit 34, the tolerance value is set in the auxiliary manufacturing apparatus 100. The parameter input unit 34 functions as a tolerance value setting unit. The parameter input unit 34 outputs the input tolerance value to the NC device 1.

[0065] The operation amount readjustment unit 33 readjusts the laser output or the material supply. Here, readjustment refers to the operation amount readjustment unit 33 further adjusting at least one of the laser output and the material supply when the laser output has been adjusted by the weld width correction control unit 31, or when the material supply has been adjusted by the weld height correction control unit 32. Details of the readjustment performed by the operation amount readjustment unit 33 will be described later.

[0066] When the laser output is readjusted, the operation quantity readjustment unit 33 outputs a laser output command indicating the readjusted laser output value to the laser oscillator 2. When the laser output is not readjusted, the operation quantity readjustment unit 33 outputs a laser output command indicating the laser output value input from the weld width correction control unit 31 to the laser oscillator 2. When the material supply quantity is readjusted, the operation quantity readjustment unit 33 outputs a material supply command indicating the readjusted material supply quantity value to the material supply device 5. When the material supply quantity is not readjusted, the operation quantity readjustment unit 33 outputs a material supply command indicating the material supply quantity value input from the weld height correction control unit 32 to the material supply device 5.

[0067] Next, the relationship between the correction of weld width and weld height will be explained. The correction of weld width is mainly achieved by adjusting the heat source output. The correction of weld height is mainly achieved by adjusting the material supply. When correcting either weld width or weld height, sometimes one of the heat source output and the material supply may be limited depending on the relationship between them.

[0068] Figure 3 is a first figure illustrating the relationship between laser output and material supply in the auxiliary manufacturing apparatus 100 according to Embodiment 1. Figure 4 is a second figure illustrating the relationship between laser output and material supply in the auxiliary manufacturing apparatus 100 according to Embodiment 1. Figure 5 is a third figure illustrating the relationship between laser output and material supply in the auxiliary manufacturing apparatus 100 according to Embodiment 1.

[0069] Figures 3 through 5 illustrate the entry of wire 14 into the laser beam L. At the tip of wire 14, which exits from the material supply nozzle 13, the temperature of wire 14 reaches its melting point. Figure 3 shows the tip of wire 14 positioned near the center line CN of the laser beam L. The position of the tip of wire 14 is determined by the laser output and the material supply amount. The double arrows in Figure 3 indicate how the position of the tip of wire 14 changes due to the laser output and the material supply amount.

[0070] When the material supply is too small relative to the laser output, the tip of the wire 14 gradually moves closer to the material supply nozzle 13. That is, the tip of the wire 14 retracts. The left side of Figure 4 shows the situation where the tip of the wire 14 retracts to near the boundary where the wire 14 enters the laser beam L. In this case, sometimes the molten material is not applied to the workpiece 19, but accumulates at the tip of the wire 14, resulting in the phenomenon of molten material clumps, i.e., molten droplets 41, remaining on the wire 14. When this molten droplet phenomenon occurs, it becomes difficult for the attachment manufacturing apparatus 100 to continue processing through the proper formation of the weld bead 16.

[0071] To avoid the dripping phenomenon shown on the left side of Figure 4, it is necessary to increase the material supply or decrease the laser output compared to the state shown on the left side of Figure 4. For example, if the tip of the wire 14 is positioned on the negative X-direction side compared to the dashed line 48 shown on the right side of Figure 4, it is difficult to properly form the weld bead 16. In this case, it is necessary to limit the material supply or laser output so that the tip of the wire 14 is positioned on the positive X-direction side compared to the dashed line 48.

[0072] On the other hand, when the material supply is too large relative to the laser output, the tip of the wire 14 gradually moves closer to the material supply nozzle 13 in the opposite direction. That is, the tip of the wire 14 advances. If the advance of the tip of the wire 14 continues, the wire 14 passes through the laser beam L without melting. The left side of FIG5 shows the case where the wire 14 has passed through the laser beam L. In this case, sometimes a residual phenomenon occurs where the wire 14 before melting collides with the workpiece 19. When a residual phenomenon occurs, it is difficult for the auxiliary manufacturing apparatus 100 to continue the processing performed by properly forming the weld bead 16.

[0073] To avoid the root remnant phenomenon shown on the left side of Figure 5, it is necessary to reduce the material supply or increase the laser output compared to the state shown on the left side of Figure 5. For example, if the position of the tip of the wire 14 is on the positive X-direction side compared to the dashed line 49 shown on the right side of Figure 5, it is difficult to properly form the weld bead 16. In this case, the material supply or laser output is limited so that the position of the tip of the wire 14 is on the negative X-direction side compared to the dashed line 49.

[0074] Figure 6 is a diagram illustrating an example of the relationship between the material supply and laser output obtained by positioning the tip of the wire 14 in an appropriate position in the auxiliary manufacturing apparatus 100 according to Embodiment 1. The appropriate position of the tip of the wire 14 is the position of the tip of the wire 14 when processing can continue, for example, the position between the dashed line 48 shown in Figure 4 and the dashed line 49 shown in Figure 5.

[0075] Figure 6 graphically illustrates the relationship between material supply and laser output. In Figure 6, the vertical axis represents the material supply, and the horizontal axis represents the laser output. Line 42 in Figure 6 represents the relationship between the maximum value of the laser output and the maximum linear velocity required to properly form weld bead 16. Line 43 in Figure 6 represents the relationship between the minimum value of the laser output and the minimum linear velocity required to properly form weld bead 16. The area between lines 42 and 43 in Figure 6 represents the appropriate range, or suitable range, of the material supply value relative to the laser output value required to properly form weld bead 16. The appropriate range can be described as the range of the laser output value relative to the material supply value required to properly form weld bead 16.

[0076] Next, the processing performed by the operation amount readjustment unit 33 in Embodiment 1 will be explained. The operation amount readjustment unit 33 sets a range, i.e., an appropriate range, between the material supply amount and the laser output value to appropriately form the weld bead 16. If, after adjustment in the operation amount adjustment unit, the material supply amount deviates from the appropriate range relative to the laser output value, the operation amount readjustment unit 33 selects either the material supply amount or the laser output value as the operation amount prioritizing adjustment, and readjusts the selected operation amount preferentially. That is, after adjusting the laser output in the weld bead width correction control unit 31, or after adjusting the material supply amount in the weld bead height correction control unit 32, if the material supply amount deviates from the appropriate range relative to the laser output value, the operation amount readjustment unit 33 preferentially readjusts the selected operation amount preferentially. Furthermore, if an allowable error amount is set in the parameter input unit 34, the operation amount readjustment unit 33 readjusts the laser output and the material supply amount considering the set allowable error amount.

[0077] In Embodiment 1, when the material supply becomes too large relative to the laser output due to the adjustment of the laser output in the weld width correction control unit 31 or the adjustment of the material supply in the weld height correction control unit 32, the operation amount readjustment unit 33 selects the operation amount that prioritizes the adjustment and readjusts the selected operation amount.

[0078] Figure 7 is a first figure explaining the selection of the operation amount that prioritizes adjustment implemented by the operation amount readjustment unit 33 of the auxiliary manufacturing apparatus 100 according to Embodiment 1. In Figure 7, similar to Figure 6, the relationship between the material supply amount and the laser output is graphically represented. The points shown in the graph of Figure 7 represent groups of values ​​for laser output and material supply amount.

[0079] Point 44 in Figure 7 represents an example of a combination of laser output and material supply values ​​after adjustments to the laser output in the weld width correction control unit 31 or the material supply amount in the weld height correction control unit 32. The laser output and material supply values ​​shown at point 44 are outside the appropriate range. In Figure 7, point 44 is positioned higher than line 42. This indicates that the material supply value exceeds the maximum value required to properly form the weld bead 16.

[0080] To bring the laser output and material supply values ​​into a suitable range, such as a set of values ​​for both, consider a readjustment from point 44 to point 45, or from point 44 to point 46. A readjustment from point 44 to point 45 means increasing the laser output without changing the material supply. A readjustment from point 44 to point 46 means decreasing the material supply without changing the laser output.

[0081] Figure 8 is a second figure explaining the selection of the operation amount that prioritizes adjustment in the operation amount readjustment unit 33 of the auxiliary manufacturing apparatus 100 according to Embodiment 1. Here, a first example of a phenomenon that may occur if the material supply amount is reduced instead of the laser output is described. If the material supply amount is reduced, the error in the weld height cannot be corrected, and the error in the weld height will increase as processing continues.

[0082] Figure 8 schematically illustrates the situation where unevenness occurs on the upper surface of the workpiece 19 due to errors in weld height. This unevenness creates a portion on the upper surface of the workpiece 19 that is tilted relative to the horizontal direction. If this tilt is greater than the tilt of the wire 14 relative to the horizontal direction, as shown in Figure 8, interference may occur between the wire 14 or the material supply nozzle 13 and the workpiece 19. If interference occurs between the wire 14 or the material supply nozzle 13 and the workpiece 19, the processing can easily become unstable.

[0083] Figure 9 is a third figure explaining the selection of the operation amount that prioritizes adjustment implemented by the operation amount readjustment unit 33 of the auxiliary manufacturing apparatus 100 according to Embodiment 1. Here, a second example of a phenomenon that may occur if the material supply is reduced instead of the laser output is performed during readjustment is explained. In Figure 9, similar to the case shown in Figure 8, it is assumed that unevenness is generated on the upper surface of the workpiece 19. In Figure 9, the irradiation of the laser beam L in each of the portions with different degrees of inclination relative to the horizontal direction is schematically shown.

[0084] As shown in Figure 9, the area of ​​the molten portion in the workpiece 19 changes between sections with varying degrees of inclination. The greater the inclination, the larger the area of ​​the molten portion. If the area of ​​the molten portion changes during the formation of the weld bead 16, the processing easily becomes unstable. Even when the width of the laser beam L is adjusted to keep the area of ​​the molten portion constant, the variation in laser output becomes larger.

[0085] As described above, if the material supply of the auxiliary manufacturing apparatus 100 is too large relative to the laser output, and the material supply is reduced instead of the laser output during readjustment, the processing can easily become unstable. Because the processing becomes unstable, the auxiliary manufacturing apparatus 100 sometimes finds it difficult to continue processing.

[0086] On the other hand, when readjusting to increase laser output without reducing material supply, the weld width increases by increasing laser output. In this case, it is possible to avoid making further processing difficult. Furthermore, if the weld width increases, the shape of the object may sometimes be larger than the target shape. In this case, the shape of the object can be corrected by machining performed after additional manufacturing processes.

[0087] In the above-mentioned case, when the material supply amount becomes too large relative to the laser output, the operation amount readjustment unit 33 prioritizes increasing the laser output over decreasing the material supply amount. That is, when the material supply amount is greater than the maximum value of the appropriate range, the operation amount readjustment unit 33 selects the laser output as the operation amount that prioritizes adjustment.

[0088] For example, the operation amount readjustment unit 33, regarding the values ​​of laser output and material supply, does not perform the readjustment from point 44 to point 46 as shown in Figure 7, but instead performs the readjustment from point 44 to point 45 as shown in Figure 7. Therefore, the auxiliary manufacturing apparatus 100 can prevent situations where processing becomes difficult due to the readjustment of the operation amount.

[0089] Figure 10 is a first figure explaining the readjustment of the operating amount performed by the operating amount readjustment unit 33 of the auxiliary manufacturing apparatus 100 according to Embodiment 1. The operating amount readjustment unit 33 readjusts the operating amount, i.e., the laser output, which prioritizes adjustment. In Figure 10, an example is explained in the case where no permissible weld height error, i.e., the allowable error amount, is set. That is, in the example shown in Figure 10, the operating amount readjustment unit 33 readjusts the laser output so that the weld height error is zero.

[0090] Figure 10(a) shows the situation before the weld bead 16 is formed in the workpiece 19. Unevennesses caused by weld bead height errors are generated on the upper surface of the workpiece 19 shown in Figure 10(a). The weld bead height correction control unit 32 adjusts the material supply amount indicated by the material supply command based on the weld bead height error, and outputs the adjusted material supply amount value to the operation amount readjustment unit 33. The weld bead width correction control unit 31 outputs the laser output value indicated by the laser output command to the operation amount readjustment unit 33.

[0091] Here, it is assumed that the value of the material supply amount input to the operation amount readjustment unit 33 is greater than the maximum value of the appropriate range. The operation amount readjustment unit 33 determines that the value of the material supply amount is greater than the maximum value of the appropriate range, and thus selects the laser output as the operation amount that prioritizes adjustment. The operation amount readjustment unit 33 performs a readjustment to increase the selected operation amount, that is, the laser output. Specifically, the operation amount readjustment unit 33 performs a readjustment to increase the laser output in the portion surrounded by the ellipse in FIG. 10(a), i.e., the recess, in a large quantity of molten material. In this case, the adjustment performed by the operation amount readjustment unit 33 prioritizes the weld height to approach the target value over the laser width.

[0092] Figure 10(b) shows the situation after the weld bead 16 is formed on the workpiece 19, starting from the state shown in Figure 10(a). Figure 10(b) shows the XZ cross-section of the workpiece 19 and the weld bead 16, and the XY plane of the weld bead 16. In the XZ cross-section shown in Figure 10(b), the height of the upper surface of the weld bead 16 is leveled to the target value of the weld bead height, H. The auxiliary manufacturing apparatus 100 can make the weld bead height error zero by readjusting the laser output in the operation amount readjustment unit 33.

[0093] Furthermore, in Figure 10(b), the laser output in the portion enclosed by the ellipse increases, thereby expanding the Y-direction width of this portion in the XY plane of weld bead 16. In the XY plane of weld bead 16 shown in Figure 10(b), the Y-direction width of this portion is greater than the target value W of the weld bead width.

[0094] Figure 10(c) shows the situation after the weld bead 16 has been machined from the state shown in Figure 10(b). Figure 10(c) shows an example where the portion of the weld bead 16 with a width exceeding W is removed by the machining process. The dashed line in Figure 10(c) represents the outline of the weld bead 16 before machining as shown in Figure 10(b). As described above, the shape of the object 17 can be corrected by machining as a subsequent process. Furthermore, Figure 10(c) illustrates a case where the weld bead 16 is machined with a width of W, but the machining method is arbitrary. The machining only needs to correct the outline of the object 17 obtained through the additional manufacturing process. In the above, the additional manufacturing apparatus 100 can prevent the continuation of machining from becoming difficult and can manufacture an object 17 with reduced shape error.

[0095] Figure 11 is a second figure illustrating the readjustment of the operating amount performed by the operating amount readjustment unit 33 of the auxiliary manufacturing apparatus 100 according to Embodiment 1. In Figure 11, an example is described where an acceptable weld height error, i.e., an allowable error amount, is set. In the example shown in Figure 11, the operating amount readjustment unit 33 readjusts the material supply amount so that the weld height error matches the allowable error amount, and readjusts the laser output based on the readjusted material supply amount. The operating amount readjustment unit 33 not only readjusts the operating amount that prioritizes adjustment, i.e., the laser output, but also readjusts the operating amount other than the operating amount that prioritizes adjustment, i.e., the material supply amount.

[0096] In the example shown in Figure 11, the operation amount readjustment unit 33 lowers the priority of adjusting the weld height compared to the case shown in Figure 10, thereby reducing the increase in laser output compared to the case shown in Figure 10. The reduced increase in laser output thus mitigates the increase in weld width caused by the laser output readjustment compared to the case shown in Figure 10. Through the adjustments described above, the auxiliary manufacturing apparatus 100 can bring the weld height error to within the allowable error range. Furthermore, corresponding to the mitigation of the weld width increase, the amount of cutting during machining can be reduced. Since the amount of cutting can be reduced, the time required for machining can be shortened.

[0097] Figure 11(a) shows the situation before the weld bead 16 is formed in the workpiece 19. Assume that an unevenness is generated on the upper surface of the workpiece 19 shown in Figure 11(a) due to an error in the weld bead height. The weld bead height correction control unit 32 adjusts the material supply amount indicated by the material supply command based on the weld bead height error, and outputs the adjusted material supply amount value to the operation amount readjustment unit 33. The weld bead width correction control unit 31 outputs the laser output value indicated by the laser output command to the operation amount readjustment unit 33.

[0098] Here, it is assumed that the value of the material supply input to the operation amount readjustment unit 33 is greater than the maximum value of the appropriate range. The operation amount readjustment unit 33 determines that the value of the material supply is greater than the maximum value of the appropriate range, and thus, similar to the case shown in FIG10, selects the laser output as the operation amount that prioritizes adjustment.

[0099] In the example shown in Figure 11, the tolerance amount set in the parameter input unit 34 is input to the operation amount readjustment unit 33. The operation amount readjustment unit 33 readjusts the material supply amount so that the weld height error is consistent with the tolerance amount. In addition, the operation amount readjustment unit 33 readjusts the value of increasing the laser output so that the readjusted material supply amount is less than or equal to the maximum value of an appropriate range in relation to the laser output. In this manner, the operation amount readjustment unit 33 readjusts the laser output and the material supply amount considering the set tolerance amount.

[0100] Figure 11(b) shows the situation after the weld bead 16 is formed on the workpiece 19, starting from the state shown in Figure 11(a). Figure 11(b) shows the XZ cross-section of the workpiece 19 and the weld bead 16, as well as the upper surface of the weld bead 16. In the XZ cross-section shown in Figure 11(b), the height error of the upper surface of the weld bead 16, i.e., the weld bead height error, is consistent with the allowable error amount, EH. As described above, by readjusting the material supply amount in the operation amount readjustment unit 33, a weld bead height error equivalent to the allowable error amount remains in the weld bead 16.

[0101] Furthermore, in Figure 11(b), the laser output in the portion enclosed by the ellipse increases, thereby expanding the Y-direction width of that portion in the XY plane of weld bead 16. However, the increase in laser output is smaller compared to the case shown in Figure 10(b), therefore the degree of expansion of weld bead width is smaller compared to the case shown in Figure 10(b). The dashed line shown in Figure 11(b) is used as a reference to the outline of weld bead 16 in the case shown in Figure 10(b).

[0102] Figure 11(c) shows the weld bead 16 after machining from the state shown in Figure 11(b). Figure 11(c) shows an example where a portion of the weld bead 16 exceeding W in width is removed by machining. The dashed line in Figure 11(c) represents the outline of the weld bead 16 before machining, as shown in Figure 11(b). In the example shown in Figure 11, the increase in weld bead width is mitigated compared to the example shown in Figure 10, and correspondingly, the amount of material removed during machining is reduced.

[0103] Figure 12 is a diagram illustrating the readjustment of the operating quantity when an allowable error amount is set in Embodiment 1. In Figure 12, similar to Figure 6, the relationship between the material supply amount and the laser output is graphically represented. The points shown in the graph of Figure 12 represent groups of laser output values ​​and material supply amount values.

[0104] Point 51 in Figure 12 represents an example of a group of values ​​for the laser output and the material supply after adjustment of the laser output in the weld width correction control unit 31 or the material supply after adjustment of the material supply in the weld height correction control unit 32. In the group represented by point 51, the value of the material supply exceeds the maximum value of the material supply required to properly form the weld bead 16.

[0105] Point 53 in Figure 12 represents an example of a set of readjusted laser output and material supply values ​​without setting a tolerance for beam height error. The transition from point 51 to point 53 in Figure 12 represents a readjustment that improves laser output without changing the material supply.

[0106] Point 52 in Figure 12 represents an example of a set of values ​​for the readjusted laser output and material supply when a tolerance for beam height error is set. The transition from point 51 to point 52 in Figure 12 represents a readjustment that reduces the material supply and increases the laser output. The increase in laser output during the transition from point 51 to point 52 is smaller than the increase in laser output during the transition from point 51 to point 53. As described above, the auxiliary manufacturing apparatus 100 is set with a tolerance for weld height error, thereby reducing the increase in laser output. By reducing the increase in laser output, the auxiliary manufacturing apparatus 100 can mitigate the widening of the weld width.

[0107] The auxiliary manufacturing apparatus 100 can reduce weld height error in any case, whether or not a tolerance value is set. When no tolerance value is set, the auxiliary manufacturing apparatus 100 can make the weld height error zero. When a tolerance value is set, the auxiliary manufacturing apparatus 100 can bring the weld height error to the tolerance value and can mitigate the widening of the weld width.

[0108] Next, the sequence of processes performed by the operation amount readjustment unit 33 will be explained. Figure 13 is a flowchart showing an example of the process sequence performed by the operation amount readjustment unit 33 of the auxiliary manufacturing apparatus 100 according to Embodiment 1. Figure 13 shows an example of the process sequence when a tolerance amount for beam height error is set.

[0109] The weld width correction control unit 31 adjusts the laser output based on the weld width error. The weld width correction control unit 31 outputs the laser output value. The weld height correction control unit 32 adjusts the material supply amount based on the weld height error. The weld height correction control unit 32 outputs the material supply amount value. The operation amount readjustment unit 33 inputs the laser output value and the material supply amount value.

[0110] In step S11, the operation amount readjustment unit 33 determines whether the material supply amount is too large relative to the laser output. If the material supply amount is greater than the maximum value of an appropriate range, the operation amount readjustment unit 33 determines that the material supply amount is too large relative to the laser output. If the material supply amount is determined to be too large relative to the laser output (step S11, Yes), the operation amount readjustment unit 33 proceeds to step S12. On the other hand, if the material supply amount is determined not to be too large relative to the laser output (step S11, No), the operation amount readjustment unit 33 proceeds to step S14.

[0111] In step S12, the operation amount readjustment unit 33 adjusts the material supply amount accordingly to the allowable amount of weld height error relative to the target value of the weld height. The operation amount readjustment unit 33 adjusts the material supply amount to reduce the amount of material supply so that the weld height error is consistent with the allowable error amount.

[0112] In step S13, the operation amount readjustment unit 33 adjusts the laser output accordingly to the material supply amount adjusted in step S12. The operation amount readjustment unit 33 increases the laser output so that the value of the material supply amount is less than or equal to the maximum value within an appropriate range in the relationship between the laser output and the material supply amount.

[0113] In step S14, the operation quantity readjustment unit 33 outputs an operation quantity. That is, the operation quantity readjustment unit 33 outputs a value for the laser output as the operation quantity and a value for the material supply quantity as the operation quantity. The operation quantity readjustment unit 33 outputs a laser output command indicating the readjusted laser output value to the laser oscillator 2. The operation quantity readjustment unit 33 outputs a material supply command indicating the readjusted material supply quantity value to the material supply device 5. The operation quantity readjustment unit 33 then concludes the processing involved in the sequence shown in FIG13.

[0114] In the above description, when the value of the material supply input to the operation amount readjustment unit 33 is greater than the maximum value of the appropriate range, the operation amount readjustment unit 33 prioritizes laser output over material supply. That is, the adjustment performed by the operation amount readjustment unit 33 prioritizes bringing the weld height closer to the target value over bringing the weld width closer to the target value. In Embodiment 1, when the value of the material supply input to the operation amount readjustment unit 33 is greater than the maximum value of the appropriate range, the operation amount readjustment unit 33 can prioritize material supply over laser output. That is, the adjustment performed by the operation amount readjustment unit 33 can prioritize bringing the weld width closer to the target value over bringing the weld height closer to the target value. For example, if an excessively large value is set as the allowable weld height error, i.e., the allowable error amount, the operation amount readjustment unit 33 can skip laser output readjustment and only readjust the material supply. The auxiliary manufacturing device 100 can arbitrarily adjust the ratio of weld height adjustment to weld width adjustment by arbitrarily setting the allowable error amount.

[0115] According to Embodiment 1, when the material supply amount in the operation amount adjustment unit 33 deviates from the value of the laser output relative to the material supply amount in the operation amount adjustment unit or after the adjustment of the laser output from an appropriate range, the operation amount readjustment unit 33 selects one of the material supply amount and the laser output as the operation amount prioritizing adjustment. The operation amount readjustment unit 33 preferentially readjusts the selected operation amount. When the value of the material supply amount is greater than the maximum value of the appropriate range, the operation amount readjustment unit 33 selects the laser output as the operation amount prioritizing adjustment. The auxiliary manufacturing apparatus 100 can reduce the shape error of the weld bead 16 by adjusting the material supply amount or the laser output in the operation amount adjustment unit, and can prevent the continuation of processing from becoming difficult by reading the operation amount in the operation amount readjustment unit 33. As described above, the auxiliary manufacturing apparatus 100 has the effect of being able to manufacture a shaped object 17 with reduced error.

[0116] Implementation method 2.

[0117] In Embodiment 1, the case where the material supply becomes excessive relative to the laser output due to adjustments in the laser output of the weld width correction control unit 31 or the material supply amount of the weld height correction control unit 32 is described. In Embodiment 2, the processing of the operation amount readjustment unit 33 in the case where the material supply becomes excessive relative to the laser output due to adjustments in the laser output of the weld width correction control unit 31 or the material supply amount of the weld height correction control unit 32 is described.

[0118] The auxiliary manufacturing apparatus 100 according to Embodiment 2 has the same structure as the auxiliary manufacturing apparatus 100 shown in FIG. 1. Furthermore, the auxiliary manufacturing apparatus 100 according to Embodiment 2 has the same functional structure as the functional structure shown in FIG. 2. In Embodiment 2, the same reference numerals are used for the same constituent elements as in Embodiment 1, and the description mainly focuses on the structures that differ from those in Embodiment 1.

[0119] In Embodiment 2, when the material supply becomes too small relative to the laser output due to the adjustment of the laser output in the weld width correction control unit 31 or the adjustment of the material supply in the weld height correction control unit 32, the operation amount readjustment unit 33 selects the operation amount that prioritizes the adjustment and readjusts the selected operation amount.

[0120] Furthermore, when the allowable error amount is set in the parameter input unit 34, the operation amount readjustment unit 33 readjusts the laser output and material supply amount considering the set allowable error amount. In Embodiment 2, the allowable error amount is the value of the weld width error that can be tolerated. In Embodiment 2, the value of the allowable weld width error is input to the parameter input unit 34. By inputting the allowable error amount to the parameter input unit 34, the allowable error amount is set in the auxiliary manufacturing apparatus 100.

[0121] Figure 14 is a diagram illustrating the selection of the operation amount that prioritizes adjustment, implemented by the operation amount readjustment unit 33 of the auxiliary manufacturing apparatus 100 according to Embodiment 2. In Figure 14, similar to Figure 6, the relationship between the material supply amount and the laser output is graphically represented. The points shown in the graph of Figure 14 represent groups of laser output values ​​and material supply amount values.

[0122] Point 54 in Figure 14 represents an example of a combination of laser output and material supply values ​​after adjustments to the laser output in the weld width correction control unit 31 or the material supply amount in the weld height correction control unit 32. The laser output and material supply values ​​shown at point 54 are outside the appropriate range. In Figure 14, point 54 is located lower than line 43. This indicates that the material supply amount is less than the minimum material supply amount required to properly form the weld bead 16.

[0123] To bring the laser output and material supply values ​​into an appropriate range, for example, for a set of laser output and material supply values, consider readjusting the transition from point 54 to point 55, or from point 54 to point 56. A transition from point 54 to point 55 means increasing the material supply without changing the laser output. A transition from point 54 to point 56 means decreasing the laser output without changing the material supply.

[0124] If the material supply is too small relative to the laser output, reducing the laser output will result in an excessively small weld width, which may sometimes cause defects in the finished product 17. During additional manufacturing processes, defects may occur that make further processing difficult due to the error in the residual weld height. In Embodiment 2, the operation amount readjustment unit 33 prioritizes increasing the material supply over decreasing the laser output when the material supply is too small relative to the laser output. That is, when the material supply value is less than the minimum value of an appropriate range, the operation amount readjustment unit 33 selects the material supply as the operation amount that prioritizes adjustment.

[0125] For example, the operation quantity readjustment unit 33 does not perform the readjustment of the laser output value and the material supply value as shown in FIG14 from point 54 to point 56, but instead performs the readjustment of ...

[0126] Figure 15 is a first figure illustrating the readjustment of the operating amount performed by the operating amount readjustment unit 33 of the auxiliary manufacturing apparatus 100 according to Embodiment 2. The operating amount readjustment unit 33 readjusts the operating amount, i.e., the material supply amount, prioritizing the adjustment. In Figure 15, an example is described where no permissible weld width error, i.e., the allowable error amount, is set. That is, in the example shown in Figure 15, the operating amount readjustment unit 33 readjusts the laser output to make the weld width error zero.

[0127] Figure 15 shows the situation after the weld bead 16 is formed on the workpiece 19. Figure 15 shows the XY plane and the XZ cross-section of the weld bead 16. In the XY plane of the weld bead 16 shown in Figure 15, the width of the weld bead 16 is leveled by the target value of the weld bead width, i.e., W. The auxiliary manufacturing apparatus 100 can make the weld bead width error zero by readjusting the laser output in the operation amount readjustment unit 33.

[0128] Furthermore, the increased material supply results in a portion of weld 16 that is higher than the target weld height (H) in the XZ cross-section shown in Figure 15. If the weld height error becomes large, processing can easily become unstable, as explained in Embodiment 1. The operation amount readjustment unit 33 prevents the weld height error from becoming large by setting an allowable weld width error (i.e., an allowable error amount).

[0129] Figure 16 is a second figure illustrating the readjustment of the operating amount performed by the operating amount readjustment unit 33 of the auxiliary manufacturing apparatus 100 according to Embodiment 2. In Figure 16, an example is described where an acceptable weld bead width error, i.e., an allowable error amount, is set. In the example shown in Figure 16, the operating amount readjustment unit 33 readjusts the laser output so that the weld bead width error matches the allowable error amount, and readjusts the material supply amount based on the readjusted laser output. The operating amount readjustment unit 33 not only readjusts the operating amount that prioritizes adjustment, i.e., the material supply amount, but also readjusts the operating amount other than the operating amount that prioritizes adjustment, i.e., the laser output.

[0130] In the example shown in Figure 16, compared to the case shown in Figure 15, the operation amount readjustment unit 33 lowers the priority of adjusting the weld width, thereby reducing the increase in material supply compared to the case shown in Figure 15. The reduced increase in material supply thus mitigates the increase in weld height achieved through material supply readjustment compared to the case shown in Figure 15. Through the adjustments described above, the auxiliary manufacturing apparatus 100 can bring the weld width error to a permissible error level. Furthermore, by mitigating the increase in weld height, the auxiliary manufacturing apparatus 100 can reduce the weld height error.

[0131] Figure 16 shows the situation after the weld bead 16 is formed on the workpiece 19. Figure 16 shows the XY plane and the XZ cross-section of the weld bead 16. On the upper surface of the weld bead 16 shown in Figure 16, the width error of the weld bead 16, i.e., the weld bead width error, is consistent with the allowable error amount, i.e., EW. As described above, by readjusting the laser output in the operation amount readjustment unit 33, a weld bead width error equivalent to the allowable error amount remains in the weld bead 16.

[0132] Furthermore, by readjusting the material supply, the degree of weld height expansion is reduced compared to the case shown in Figure 15. The dashed line on the XZ cross-section shown in Figure 16 represents the upper surface of weld 16 in the case shown in Figure 15. The additional manufacturing apparatus 100 reduces the degree of weld height expansion, thereby reducing weld height error.

[0133] Figure 17 is a diagram illustrating the readjustment of the operating quantity when an allowable error amount is set in Embodiment 2. In Figure 17, similar to Figure 6, the relationship between the material supply amount and the laser output is graphically represented. The points shown in the graph of Figure 17 represent groups of laser output values ​​and material supply amount values.

[0134] Point 54 in Figure 17 is set to be the same as point 54 in Figure 14. Point 58 in Figure 17 represents an example of a set of readjusted laser output and material supply values ​​without setting a tolerance for weld width error. The transition from point 54 to point 58 in Figure 17 represents a readjustment that increases the material supply without changing the laser output.

[0135] Point 57 in Figure 17 represents an example of a set of readjusted laser output and material supply values ​​when a tolerance for weld width error is set. The transition from point 54 to point 57 in Figure 17 represents a readjustment that increases the material supply and decreases the laser output. The increase in material supply during the transition from point 54 to point 57 is less than the increase in material supply during the transition from point 54 to point 58. The auxiliary manufacturing apparatus 100 reduces the increase in material supply, thereby mitigating the increase in weld height by setting a tolerance for weld width error.

[0136] The auxiliary manufacturing apparatus 100 can reduce the weld width error in any case, whether or not a tolerance value is set. When no tolerance value is set, the auxiliary manufacturing apparatus 100 can make the weld width error zero. When a tolerance value is set, the auxiliary manufacturing apparatus 100 can bring the weld width error to the tolerance value and reduce the weld height error.

[0137] Next, the sequence of processes performed by the operation amount readjustment unit 33 will be explained. Figure 18 is a flowchart showing an example of the process sequence performed by the operation amount readjustment unit 33 of the auxiliary manufacturing apparatus 100 according to Embodiment 2. Figure 18 shows an example of the process sequence when a tolerance amount for weld width error is provided.

[0138] The weld width correction control unit 31 adjusts the laser output based on the weld width error. The weld width correction control unit 31 outputs the laser output value. The weld height correction control unit 32 adjusts the material supply amount based on the weld height error. The weld height correction control unit 32 outputs the material supply amount value. The operation amount readjustment unit 33 inputs the laser output value and the material supply amount value.

[0139] In step S21, the operation amount readjustment unit 33 determines whether the material supply amount is too small relative to the laser output. If the material supply amount is less than the minimum value of the appropriate range, the operation amount readjustment unit 33 determines that the material supply amount is too small relative to the laser output. If the material supply amount is determined to be too small relative to the laser output (step S21, Yes), the operation amount readjustment unit 33 proceeds to step S22. On the other hand, if the material supply amount is determined to be not too small relative to the laser output (step S21, No), the operation amount readjustment unit 33 proceeds to step S24.

[0140] In step S22, the operation amount readjustment unit 33 adjusts the laser output accordingly to match the allowable amount of weld width error relative to the target value of the weld width. The operation amount readjustment unit 33 adjusts to reduce the laser output so that the weld width error is consistent with the allowable error amount.

[0141] In step S23, the operation amount readjustment unit 33 adjusts the material supply amount in accordance with the laser output adjusted in step S22. The operation amount readjustment unit 33 increases the material supply amount so that the value of the material supply amount in the relationship between the laser output and the material supply amount is greater than or equal to the minimum value of an appropriate range.

[0142] In step S24, the operation quantity readjustment unit 33 outputs an operation quantity. That is, the operation quantity readjustment unit 33 outputs a value for the laser output as the operation quantity and a value for the material supply quantity as the operation quantity. The operation quantity readjustment unit 33 outputs a laser output command indicating the readjusted laser output value to the laser oscillator 2. The operation quantity readjustment unit 33 outputs a material supply command indicating the readjusted material supply quantity value to the material supply device 5. The operation quantity readjustment unit 33 then concludes the processing involved in the sequence shown in FIG18.

[0143] In the above description, when the value of the material supply input to the operation amount readjustment unit 33 is less than the minimum value of the appropriate range, the operation amount readjustment unit 33 prioritizes the material supply over the laser output when performing readjustment. That is, the adjustment performed by the operation amount readjustment unit 33 prioritizes the weld width over the weld height. In Embodiment 2, when the value of the material supply input to the operation amount readjustment unit 33 is less than the minimum value of the appropriate range, the operation amount readjustment unit 33 can prioritize the laser output over the material supply. That is, the adjustment performed by the operation amount readjustment unit 33 can prioritize the weld height over the weld width. For example, if an excessively large value is set as the allowable weld width error, the operation amount readjustment unit 33 may not perform readjustment of the material supply, but only readjustment of the laser output. The auxiliary manufacturing device 100 can arbitrarily adjust the ratio of weld width adjustment to weld height adjustment by arbitrarily setting the allowable error amount.

[0144] Furthermore, in actual additional manufacturing processes, defects may not necessarily occur in the form 17 even if the weld width is less than the target value. The allowable error for weld width is appropriately set, thereby preventing defects from occurring even when the weld width is less than the target value.

[0145] Figure 19 is a diagram illustrating the relationship between the allowable error amount in the auxiliary manufacturing apparatus 100 according to Embodiment 2 and the occurrence of defects in the finished product 17. In the following description, the width of the overlapping portion between adjacent weld beads 16 is referred to as the overlap amount. The width of the overlapping portion between weld beads 16 is the width in the direction in which the weld beads 16 are arranged. Furthermore, the distance between the center positions of one adjacent weld bead 16 and the center position of the other is referred to as the weld bead center-to-center distance. The weld bead center-to-center distance is predetermined through a processing procedure, etc.

[0146] The amount of overlap can be calculated using the following formula.

[0147] Overlap

[0148] = (Actual weld width) - (Weld center-to-center distance)

[0149] = (Target value of weld width) - (Tolerance for weld width error) - (Distance between weld centers)

[0150] Figures 19(a), (b), and (c) show examples of the arrangement of two adjacent weld passes 16. In Figures 19(a), (b), and (c), P represents the distance between the center-to-center of the weld passes. When the overlap factor O is greater than zero, the two weld passes 16 overlap each other, and no defects are generated.

[0151] In the case shown in Figure 19(a), the weld width of each weld pass 16 is consistent with the target value, W. That is, the actual weld width of each weld pass 16 is W. In the case shown in Figure 19(a), the allowable error amount of weld width error, EW, is set to zero. In the case shown in Figure 19(a), the overlap amount O is greater than zero, therefore no defects are generated.

[0152] In the case shown in Figure 19(b), the weld width W' of each weld pass 16 is less than the target value W, and a tolerance amount EW for the weld width error is set. In the case shown in Figure 19(b), 0 < EW < W - P holds true. In this case, O', which is the overlap amount, is greater than zero, so no defect occurs.

[0153] In the case shown in Figure 19(c), the weld width W' of each weld pass 16 is less than the target value W, and a tolerance amount EW for the weld width error is set. In the case shown in Figure 19(c), 0 < W - P < EW holds true. In this case, the overlap amount O' is less than zero, that is, the two weld passes 16 do not overlap each other, thus causing a defect.

[0154] The allowable error of weld width error satisfies the following conditions, thereby enabling the additional manufacturing device 100 to avoid the generation of defects.

[0155] (Tolerant error in weld width) < (Target value of weld width) - (Distance between weld centers)

[0156] According to Embodiment 2, when the material supply amount in the operation amount adjustment unit 33 deviates from the laser output value from an appropriate range relative to the material supply amount in the operation amount adjustment unit, or after the laser output adjustment, the material supply amount deviates from the laser output value, the operation amount readjustment unit 33 selects one of the material supply amount and laser output as the operation amount prioritizing adjustment. The operation amount readjustment unit 33 preferentially readjusts the selected operation amount. When the material supply amount value is less than the minimum value of the appropriate range, the operation amount readjustment unit 33 selects the material supply amount as the operation amount prioritizing adjustment. The auxiliary manufacturing apparatus 100 can reduce the shape error of the weld bead 16 by adjusting the material supply amount or laser output in the operation amount adjustment unit, and can prevent the processing from becoming difficult by reading the operation amount in the operation amount readjustment unit 33. In summary, the auxiliary manufacturing apparatus 100 has the effect of being able to manufacture a shaped object 17 with reduced error.

[0157] The auxiliary manufacturing apparatus 100 can perform both the process described in Embodiment 1 and the process described in Embodiment 2. That is, when the material supply is too large relative to the appropriate range, the auxiliary manufacturing apparatus 100 can perform the process described in Embodiment 1, and when the material supply is too small relative to the appropriate range, it can perform the process described in Embodiment 2.

[0158] Implementation method 3.

[0159] During additional manufacturing processes, due to thermal deviations, an error may sometimes occur at the center position of the weld bead 16 to be formed relative to the target position. This error affects the shape of the molded object 17, sometimes resulting in a shape that differs from the target shape. In response to this phenomenon, if the position of the processing point is corrected based on the measurement of the error at the center position of the weld bead 16, the position correction amount may be too large, potentially causing the weld bead 16 to form at a location where it separates from the substrate 18 or the molded object 17 on the substrate 18. If the position correction amount is too large, processing cannot continue if the weld bead 16 cannot contact the substrate 18 or the molded object 17. Furthermore, if only the position correction amount is limited, it is difficult to obtain the molded object 17 with the target shape.

[0160] In embodiment 3, when the position correction amount is limited, the shape of the object 17 is corrected to be close to the target shape by increasing the adjustment of the weld width, that is, by increasing the adjustment of the laser output.

[0161] Figure 20 is a diagram showing an example of the functional structure of the additional manufacturing apparatus 100A according to Embodiment 3. Figure 20 shows an example of a functional structure related to reducing the error in the center position of the weld bead 16, i.e., the weld bead position error. Furthermore, the example shown in Figure 20 also has the same structure as the structure shown in Figure 2, namely, a functional structure related to reducing the shape error of the weld bead 16. In Embodiment 3, the same reference numerals are used for the same constituent elements as in Embodiment 1 or 2, and the structures different from those in Embodiment 1 or 2 are mainly described.

[0162] The difference between the auxiliary manufacturing apparatus 100A and the auxiliary manufacturing apparatus 100 shown in FIG1 is that the NC device 1A is provided instead of the NC device 1. The structure of the auxiliary manufacturing apparatus 100A, except for the NC device 1A, is the same as that of the auxiliary manufacturing apparatus 100 shown in FIG1.

[0163] The NC device 1A is a control device that controls the entire auxiliary manufacturing device 100A. The NC device 1A includes a weld width correction control unit 31, a weld height correction control unit 32, an operation amount readjustment unit 33, a position correction unit 61, a position correction amount adjustment unit 62, and a weld width correction amount calculation unit 63.

[0164] The analysis device 6 analyzes the image input from the camera 7 shown in Figure 1, thereby determining the weld position error. The analysis device 6 outputs the value of the weld position error, i.e., the cycle position error, to the NC device 1A.

[0165] The weld position error calculated by the analysis device 6 is input to the position correction unit 61. If the weld position error is input, the position correction unit 61 calculates the correction amount for the machining point based on the weld position error. The position correction unit 61 outputs the calculated correction amount to the position correction amount adjustment unit 62.

[0166] The value representing the appropriate correction range is input as a parameter value to the parameter input unit 34. The appropriate correction range is the range of values ​​of the correction amount of the machining point that can be properly formed when the weld bead 16 is formed. The value representing the appropriate correction range is input to the parameter input unit 34, thereby setting the appropriate correction range in the auxiliary manufacturing device 100. The parameter input unit 34 outputs the value representing the appropriate correction range to the NC device 1A.

[0167] When the value of the correction amount obtained by the position correction unit 61 deviates from the appropriate correction range indicated by the value input by the parameter input unit 34, the position correction amount adjustment unit 62 adjusts the value of the correction amount to a value included in the appropriate correction range. Based on the adjusted correction amount, the position correction amount adjustment unit 62 corrects the position indicated by the position command. The position correction amount adjustment unit 62 outputs the corrected position command to the shaft drive device 3.

[0168] The position correction adjustment unit 62 determines whether the shape of the object 17 can be set to the target shape using the adjusted correction amount. If the value of the correction amount obtained by the position correction unit 61 deviates from the appropriate correction range, the position correction adjustment unit 62 determines that the shape of the object 17 cannot be set to the target shape. The position correction adjustment unit 62 calculates the difference between the shape of the object 17 and the target shape when the machining point has been corrected using the correction amount adjusted by the position correction adjustment unit 62. The position correction adjustment unit 62 outputs the calculated value representing the difference to the weld width correction amount calculation unit 63.

[0169] If a value representing the difference is input to the weld width correction calculation unit 63, the unit calculates the correction amount for the weld width based on that value. Specifically, the weld width correction calculation unit 63 calculates the correction amount for the weld width, i.e., the weld width correction amount, based on the difference between the shape of the workpiece 17 and the target shape, after the machining point has been corrected using the correction amount adjusted by the position correction adjustment unit 62. The weld width correction calculation unit 63 outputs the calculated correction amount value to the weld width correction control unit 31 and the weld height correction control unit 32, respectively.

[0170] Similar to Embodiment 1 or 2, if a weld width error is input to the weld width correction control unit 31, the laser output indicated by the laser output command is adjusted based on the weld width error. Additionally, the weld width correction control unit 31 corrects the laser output based on the correction amount value input from the weld width correction amount calculation unit 63. If a weld height error is input to the weld height correction control unit 32, the material supply amount indicated by the material supply command is adjusted based on the weld height error. Additionally, the weld height correction control unit 32 corrects the material supply amount based on the correction amount value input from the weld width correction amount calculation unit 63. The operation amount adjustment unit corrects at least one of the laser output and the material supply amount based on the weld width correction amount. Through the correction of the laser output in the weld width correction control unit 31 and the correction of the material supply amount in the weld height correction control unit 32, the weld width of the weld 16 to be formed is corrected.

[0171] Next, the relationship between the correction of the machining point corresponding to the weld position error and the formation of the weld 16 will be explained. Figure 21 is the first figure used to explain the relationship between the correction of the machining point and the formation of the weld 16 in the auxiliary manufacturing apparatus 100A according to Embodiment 3. In Figure 21(a), the case where the weld 16 is formed in the workpiece 19 is illustrated. In Figure 21(a), the machining direction is set to the Y-axis direction. The machining point is the position on the central axis of the beam nozzle. CX1 is set to the position of the central axis of the beam nozzle in the state shown in Figure 21(a).

[0172] As shown in Figure 21(a), the weld bead 16 is intended to be formed in region 65 on the outer edge of the workpiece 19. The center position of the formed weld bead 16 deviates from the center position of region 65. If the weld bead position error of the to be formed weld bead 16 becomes too large, a defect will be generated in the workpiece 17. If a defect is generated in the workpiece 17, it is sometimes difficult to continue processing.

[0173] Figure 21(b) illustrates a case where the weld bead position error, as shown in Figure 21(a), is corrected solely by adjusting the machining point. CX2 is the position of the central axis of the beam nozzle in the state shown in Figure 21(b). The distance between CX1 and CX2 corresponds to the machining point correction amount, ΔCX.

[0174] Figure 21(b) shows a state where the gap between the workpiece 19 and the corrected machining point is too large, and the weld bead 16 cannot be formed on the workpiece 19. Furthermore, in the portion of the workpiece 19 where the weld bead 16 is intended to be formed, areas 66 that are not irradiated by the laser beam L sometimes occur. As described above, the weld bead 16 cannot be formed on the workpiece 19 simply by correcting the machining point, thus sometimes making it difficult to continue processing.

[0175] Figure 22 is a second figure used to explain the relationship between the correction of the processing point and the formation of the weld bead 16 in the additional manufacturing apparatus 100A according to Embodiment 3. In Figure 22, the case of correcting the weld bead position error and correcting the weld bead width by correcting the processing point is shown. In Figure 22(a), similar to Figure 21(a), the case of forming the weld bead 16 in the workpiece 19 is shown.

[0176] In the state shown in Figure 22(b), the weld position error is set to a value that exceeds the appropriate correction range. The position correction unit 61 calculates a correction amount based on the weld position error, therefore the value of the correction amount calculated by the position correction unit 61 deviates from the appropriate correction range. The position correction amount adjustment unit 62 adjusts ΔCX, which is the position correction amount, to a value included in the appropriate correction range. The auxiliary manufacturing apparatus 100A adjusts the value of the position correction amount in the position correction amount adjustment unit 62, thereby preventing situations where further processing becomes difficult.

[0177] In the state shown in Figure 22(b), the correction amount of the processing point is limited to an appropriate correction range, thereby the shape of the molded object 17 does not meet the target shape. As shown in Figure 22(c), the weld width of the weld bead 16 to be formed is corrected to W', which is larger than the target value W. The auxiliary manufacturing apparatus 100A corrects the weld width by the weld width correction amount calculation unit 63, thereby enabling the shape of the molded object 17 to match the target shape.

[0178] Figure 23 is a diagram illustrating the correction of weld width in the additional manufacturing apparatus 100A according to Embodiment 3. In Figure 23(a), an example of weld 16 before the weld width is corrected by the weld width correction amount calculated by the weld width correction amount calculation unit 63 is shown. The weld width of weld 16 shown in Figure 23(a) is the target value W for the weld width. The weld height of weld 16 shown in Figure 23(a) is the target value H for the weld height.

[0179] In Figure 23(b), an example of weld bead 16 is shown where only the weld bead width has been corrected from the state shown in Figure 23(a). The weld bead width correction calculation unit 63 calculates ΔW as the weld bead width correction amount based on the difference between the shape of the object 17 and the target shape when the processing point has been corrected with the correction amount adjusted by the position correction amount adjustment unit 62. The weld bead width correction control unit 31 increases the laser output based on the value of the weld bead width correction amount input from the weld bead width correction calculation unit 63. The weld bead width of the weld bead 16 shown in Figure 23(b) is W+ΔW. However, if the laser output is increased but the material supply cannot be changed, the weld bead height of the weld bead 16 to be formed does not meet the target value H.

[0180] Figure 23(c) shows an example of weld 16 in which the weld width and weld height have been corrected from the state shown in Figure 23(a). The weld height correction control unit 32 increases the material supply based on the value of the weld width correction amount input from the weld width correction amount calculation unit 63. As a result, the auxiliary manufacturing apparatus 100A forms a weld 16 with a weld width of W+ΔW and a weld height of H, as shown in Figure 23(c).

[0181] Figure 24 is a diagram illustrating the correction amount calculated by the weld width correction amount calculation unit 63 of the auxiliary manufacturing apparatus 100A according to Embodiment 3. In Figure 24, a weld 16 with a weld position error and a contour shape 67 serving as the target shape of the shaping object 17 are shown. The weld width of the weld 16 is set to W. The correction amount ΔW calculated by the weld width correction amount calculation unit 63 corresponds to the difference between the contour shape 67 and the formed weld 16. The weld width correction amount calculation unit 63 outputs the calculated weld width correction amount value to both the weld width correction control unit 31 and the weld height correction control unit 32.

[0182] Next, the sequence of processes performed by the position correction unit 61, the position correction amount adjustment unit 62, and the weld width correction amount calculation unit 63 will be described. Figure 25 is a flowchart showing an example of the process sequence performed by the position correction unit 61, the position correction amount adjustment unit 62, and the weld width correction amount calculation unit 63 of the auxiliary manufacturing apparatus 100A according to Embodiment 3.

[0183] In step S31, the position correction unit 61 calculates the correction amount of the machining point based on the weld position error. The position correction unit 61 outputs the calculated correction amount value to the position correction amount adjustment unit 62.

[0184] In step S32, the position correction adjustment unit 62 determines whether the value of the correction amount calculated by the position correction unit 61 in step S31 deviates from the appropriate correction range. If it is determined that the value of the correction amount deviates from the appropriate correction range (step S32, Yes), the position correction adjustment unit 62 proceeds to step S33.

[0185] In step S33, the position correction adjustment unit 62 adjusts the value of the correction amount to a value included in an appropriate correction range. The position correction adjustment unit 62 outputs a position command, corrected based on the adjusted correction amount, to the shaft drive device 3. The position correction adjustment unit 62 calculates the difference between the shape of the object 17 and the target shape when the machining point has been corrected using the correction amount adjusted in step S33. The position correction adjustment unit 62 outputs a value representing the calculated difference to the weld width correction amount calculation unit 63.

[0186] In step S34, the weld width correction calculation unit 63 calculates the correction amount for the weld width based on the difference between the shape of the object 17 and the target shape, since the processing point has been corrected by the adjusted correction amount in step S33. The weld width correction calculation unit 63 outputs the calculated correction amount to the weld width correction control unit 31 and the weld height correction control unit 32, respectively.

[0187] If step S34 is completed, the position correction unit 61, the position correction amount adjustment unit 62, and the weld width correction amount calculation unit 63 will end the processing involved in the sequence shown in FIG25. Alternatively, if it is determined that the value of the correction amount has not deviated from the appropriate correction range (step S32, No), the position correction unit 61, the position correction amount adjustment unit 62, and the weld width correction amount calculation unit 63 will end the processing involved in the sequence shown in FIG25.

[0188] Furthermore, the auxiliary manufacturing apparatus 100A performs the process described in Embodiment 1 or the process described in Embodiment 2, together with the process described in Embodiment 3. Alternatively, the auxiliary manufacturing apparatus 100A may perform both the process described in Embodiment 1 and the process described in Embodiment 2, together with the process described in Embodiment 3.

[0189] According to Embodiment 3, when the value of the correction amount for the weld bead position error deviates from the appropriate correction range, the position correction amount adjustment unit 62 adjusts the value of the correction amount to a value included in the appropriate correction range. The weld bead width correction amount calculation unit 63 calculates the correction amount for the weld bead width based on the difference between the shape of the object 17 and the target shape when the processing point has been corrected with the correction amount adjusted by the position correction amount adjustment unit 62. The auxiliary manufacturing apparatus 100A can correct the weld bead position error and prevent the processing from becoming difficult due to excessive correction amount. The auxiliary manufacturing apparatus 100A can reduce the shape error of the weld bead 16 by correcting the weld bead width. In summary, the auxiliary manufacturing apparatus 100A has the effect of being able to manufacture an object 17 with reduced error.

[0190] Next, the hardware structure of the NC devices 1 and 1A according to embodiments 1 to 3 will be described. The NC devices 1 and 1A are implemented by processing circuits. The processing circuits may be circuits that execute software using a processor, or they may be dedicated circuits.

[0191] When the processing circuit is implemented by software, the processing circuit is, for example, the control circuit 70 shown in FIG26. FIG26 is a diagram showing a structural example of the control circuit 70 according to embodiments 1 to 3. The control circuit 70 includes an input unit 71, a processor 72, a memory 73, and an output unit 74.

[0192] The input unit 71 is an interface circuit that receives data input from outside the control circuit 70 and provides it to the processor 72. The output unit 74 is an interface circuit that sends data from the processor 72 or the memory 73 to the outside of the control circuit 70. When the processing circuit is the control circuit 70 shown in FIG. 26, the processor 72 reads the program stored in the memory 73 and executes it, thereby realizing the functions of NC devices 1 and 1A. The memory 73 is also used as temporary memory in each process performed by the processor 72.

[0193] When the processing circuit is the control circuit 70 shown in FIG. 26, the NC devices 1 and 1A are implemented by software, firmware, or a combination of software and firmware. The software or firmware is described as a program and stored in memory 73. The processing circuit implements the functions of the NC devices 1 and 1A by reading the program stored in memory 73 from the processor 72. That is, the processing circuit has memory 73, which is used to store the program that is ultimately executed in the processing of the NC devices 1 and 1A. In addition, these programs can be described as the sequence and method by which the computer executes the NC devices 1 and 1A.

[0194] Processor 72 is a CPU (Central Processing Unit), processing device, arithmetic device, microprocessor, microcomputer, processor, or DSP (Digital Signal Processor). Memory 73 is, for example, non-volatile or volatile semiconductor memory such as RAM (Random Access Memory), ROM (Read Only Memory), flash memory, EPROM (Erasable Programmable Read Only Memory), EEPROM (Electrically Erasable Programmable Read Only Memory), disk, floppy disk, optical disk, compact disk, mini disk, or DVD (Digital Versatile Disc).

[0195] Figure 26 is an example of hardware implemented using a general-purpose processor 72 and a memory 73. The NC devices 1 and 1A can be implemented using dedicated hardware circuitry. Figure 27 is a diagram showing an example of the structure of the dedicated hardware circuitry 75 according to embodiments 1 to 3.

[0196] The dedicated hardware circuit 75 includes an input section 71, an output section 74, and a processing circuit 76. The processing circuit 76 can be a single circuit, a composite circuit, a programmable processor, a parallel-programmable processor, an ASIC (Application Specific Integrated Circuit), an FPGA (Field Programmable Gate Array), or a combination thereof. Furthermore, the NC devices 1 and 1A can also be implemented by combining the control circuit 70 and the hardware circuit 75.

[0197] The PC 10 in embodiments 1 to 3 is implemented using the same hardware as that shown in FIG26. The function of the parameter input unit 34 is implemented through the input unit 71. In addition, the PC 10 has an input device operated by the user and a display device for displaying a screen. The input device includes, for example, a keyboard, mouse, keypad, or touch panel. The display device is, for example, an LCD (Liquid Crystal Display) or an organic EL (Electro-Luminescence) display.

[0198] The specific ways in which the constituent elements of the NC devices 1 and 1A are distributed or integrated as described in Embodiments 1 to 3 are not limited to those described in Embodiments 1 to 3. All or part of the constituent elements of the NC devices 1 and 1A can be functionally or physically distributed or integrated in any unit.

[0199] The structures shown in the above embodiments illustrate one example of the content of the present invention. The structures of each embodiment can be combined with other known technologies. The structures of each embodiment can also be appropriately combined with each other. Without departing from the spirit of the present invention, a portion of the structure of each embodiment can be omitted or modified.

[0200] Explanation of the label

[0201] 1. 1A NC device, 2. Laser oscillator, 3. Axis drive device, 4. Gas supply device, 5. Material supply device, 6. Analysis device, 7. Camera, 8. Processing head, 9. Gas nozzle, 10. PC, 11. Measuring equipment, 12. Material supply source, 13. Material supply nozzle, 14. Wire, 15. Melt pool, 16. Weld bead, 17. Shaper, 18. Substrate, 19. Workpiece, 20. Optical cable, 21. Worktable, 30. Shaping unit, 31. Weld bead width correction control unit, 32. Weld bead height correction control unit, 33. Operation amount readjustment unit 34 Parameter Input Unit, 41 Molten Droplet, 42, 43 Straight Line, 44, 45, 46, 51, 52, 53, 54, 55, 56, 57, 58 Points, 48, 49 Dashed Line, 61 Position Correction Unit, 62 Position Correction Amount Adjustment Unit, 63 Weld Bead Width Correction Amount Calculation Unit, 65, 66 Area, 67 Contour Shape, 70 Control Circuit, 71 Input Unit, 72 Processor, 73 Memory, 74 Output Unit, 75 Hardware Circuit, 76 Processing Circuit, 100, 100A Additional Manufacturing Device.

Claims

1. An auxiliary manufacturing apparatus, characterized in that, It includes: a shaping unit having a material supply unit that supplies material to a workpiece, a heat source output unit that outputs a heat source that melts the material, and a drive unit that moves the heat source and the material supply unit, wherein the material melted by using the heat source forms a weld bead; and an operation amount adjustment unit that adjusts the material supply amount of the material supply unit or the heat source output of the heat source output unit based on the shape error of the weld bead. The operation amount readjustment unit sets an appropriate range, i.e., an appropriate range, for the value of the material supply amount relative to the value of the heat source output when the weld bead is appropriately formed. If, after adjustment in the operation amount adjustment unit, the value of the material supply amount relative to the heat source output deviates from the appropriate range, the unit selects either the material supply amount or the heat source output as the operation amount to prioritize adjustment, based on the magnitude of the material supply amount relative to the appropriate range, and prioritizes readjusting the selected operation amount. The position correction unit calculates the correction amount for the processing point supplied with the heat source and the material based on the error in the center position of the weld bead to be formed, i.e., the weld bead position error. The system includes a correction adjustment unit that sets a range of values ​​for the correction amount that can be appropriately formed when the weld bead is formed, i.e., an appropriate correction range. When the value of the correction amount obtained by the position correction unit deviates from the appropriate correction range, the value of the correction amount is adjusted to a value included in the appropriate correction range. The system also includes a weld bead width correction calculation unit that calculates the correction amount for the weld bead width, i.e., the weld bead width correction amount, based on the difference between the shape of the object and the target shape when the processing point is corrected with the correction amount adjusted by the position correction adjustment unit. The operation amount adjustment unit corrects at least one of the heat source output and the material supply amount based on the weld bead width correction amount.

2. The auxiliary manufacturing apparatus according to claim 1, characterized in that, The operation amount adjustment unit includes: a weld width correction control unit that adjusts the heat source output based on the error of the width of the formed weld, i.e., weld width error, thereby controlling the correction of the weld width; and a weld height correction control unit that adjusts the material supply amount based on the error of the height of the formed weld, i.e., weld height error, thereby controlling the correction of the weld height. The operation amount readjustment unit, after adjusting the heat source output in the weld width correction control unit or after adjusting the material supply amount in the weld height correction control unit, preferentially readjusts the selected operation amount when the value of the material supply amount deviates from the appropriate range relative to the value of the heat source output.

3. The additional manufacturing apparatus according to claim 2, characterized in that, When the value of the material supply is greater than the maximum value of the appropriate range, the operation quantity readjustment unit selects the heat source output as the operation quantity that prioritizes adjustment.

4. The additional manufacturing apparatus according to claim 3, characterized in that, The system includes a tolerance setting unit that sets a tolerance value for the weld height error that can be tolerated. The operation amount readjustment unit readjusts the heat source output and the material supply amount by taking into account the set tolerance value.

5. The additional manufacturing apparatus according to claim 2, characterized in that, When the value of the material supply is less than the minimum value of the appropriate range, the operation quantity readjustment unit selects the material supply quantity as the operation quantity that prioritizes adjustment.

6. The additional manufacturing apparatus according to claim 5, characterized in that, The system includes a tolerance error setting unit that sets a tolerance error value for the weld width error that can be tolerated. The operation amount readjustment unit readjusts the material supply amount and the heat source output by taking into account the set tolerance error value.

7. An additive manufacturing method using the additive manufacturing apparatus of claim 1, characterized in that, The process includes the following steps: adjusting the value of the material supply amount of the material supply section that supplies material to the workpiece or the heat source output of the heat source output section that outputs heat to melt the material, based on the shape error of the weld bead formed by the material melted by the heat source. And set a range, i.e., an appropriate range, for the value of the material supply relative to the value of the heat source output when the weld bead can be formed appropriately. If the value of the material supply relative to the heat source output deviates from the appropriate range after the adjustment of the material supply or the heat source output, one of the material supply and the heat source output is selected as the operation quantity that prioritizes the adjustment based on the magnitude of the value of the material supply relative to the appropriate range, and the selected operation quantity is readjusted preferentially.

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