System for the production of three-dimensional objects

Abstract

A system (1) for producing three-dimensional objects (2) by successively solidifying layers of a radiation-hardenable build material at the locations corresponding to the respective cross-section of the object (2), wherein the system (1) comprises a plurality of individual housing units (3, 6) that can be set up at a distance from one another and at least one process station (4) for carrying out an additive manufacturing process and at least one handling station (7) for unpacking manufactured objects (2) from a construction container (5) movable between the process station (4) and the handling station (7), characterized by a tunnel chain comprising: one or more feed openings (11) which are configured to introduce several movable construction containers (5) into the tunnel chain, several tunnel sections which are integrated in separate housing units (3, 6) that can be set up separately or individually, wherein the housing units (3,6) at least one process station (4) and / or at least one handling station (7) is arranged, wherein the several tunnel sections together form a continuous tunnel, a travel path (13) for construction containers (5) and other containers or modules movable within the system, along which the movable construction containers (5) can be moved through the tunnel formed by the tunnel sections, wherein the tunnel (12) or the tunnel chain is provided in the interior of the housing units (3, 6) with side niches or extensions (16) into which the movable containers can be driven during a maneuvering operation to allow the continuous opening of the travel path (13) running in the tunnel (12) for other movable containers.

Description

The invention relates to a system for manufacturing three-dimensional objects by successively solidifying layers of a buildable material at the locations corresponding to the respective cross-section of the object. Such systems are also referred to as additive manufacturing systems and include so-called SLM (selective laser melting) or SLS (selective laser sintering) devices. However, the invention is not limited to these but also extends to other devices in which the buildable material is, for example, sprayed onto the area to be built up and melted there, e.g., by a laser beam, and solidified upon solidification in order to additively form the component. Known devices of this type typically comprise a process station where the actual layer-by-layer additive manufacturing process takes place, usually using a construction container. It is also known to arrange a handling station in a second housing or housing section for unpacking manufactured objects from the construction container, which can be moved between the at least one process station and the at least one handling station. Such a device is described, for example, in DE 20040547, where both a process station and a removal station are provided in a single, integrated housing unit, and the construction container can be moved back and forth between the two stations. This known device is disadvantageous in that, as a self-contained unit, it cannot be expanded. Furthermore, DE 10 2014 010 931 A1 provides a device of the aforementioned type with a plurality of handling stations, which are essentially arranged side by side and are arranged individually or jointly as handling modules that are displaceable, rotatable or pivotable relative to at least one assembly chamber, but coupled to it. Further prior art exists in the form of documents DE 10 2013 223 411 A1, DE 10 2009 036 153 A1 and DE 10 2009 056 696 A1, the first of which relates to a modular system for producing a three-dimensional object, the second to a device for the additive manufacturing of three-dimensional molded parts and the third to a construction box for a rapid prototyping system. The invention is based on the objective of further developing a system with the features of the preamble of claim 1 in such a way that it can be used more variably, adapted to changing requirements within a manufacturing plant and allows highly efficient fast production. This problem is solved by the features of claim 1; advantageous further developments result from the associated dependent claims. The method claims characterize the invention in terms of method. The invention is defined by the appended claims. According to the teaching of claim 1, in a first alternative, both the process station and the at least one handling station are arranged in separate housing units that can be set up independently or individually. These housing units are provided with feed openings in wall areas and are designed such that, when placed side by side, in a row, or partially separated, they can form at least one continuous tunnel or tunnel chain, wherein the tunnel or tunnel chain forms a travel path integrated into the housing units for construction containers and other movable containers. In a further alternative, it is within the scope of the invention to allow the tunnel or tunnel chain to pass through at least two housing units, each of which accommodates one or more process stations. The core of the invention is thus considered to be the creation of a tunnel travel path within the housing units, which can be freely positioned, mounted directly adjacent to one another, or spaced apart. This tunnel travel path is usable not only for the construction container but also for other containers. This means, for example, that containers from several process stations can be moved along the same travel path to a common handling station or to several designated handling stations. It is also possible, for example, to transport overflow containers with excess building material along this travel path or to move dosing containers with fresh building material into a process station. All of this takes place within a single tunnel. Furthermore, it is within the scope of the invention to provide only a series of process stations, to arrange the tunnel or tunnel sections within these stations, to connect them in a tunnel-like manner, and to carry out the preparation of the construction containers or the removal of completed components, e.g., by a robot, in a large inerted room. This inerted room then serves as a handling station and is expediently connected to the tunnel or tunnel sections. The tunnel concept, as implemented in the invention, offers several advantages. Firstly, there are no interactions between the moving containers and the operators who must be located in the periphery of such a system, thus eliminating any potential hazards. Furthermore, integrating the travel path into the device itself through the tunnel enables clean and conflict-free handling of the containers throughout the entire system. The containers can be sealed to largely maintain the protective gas atmosphere inside them. However, it is also possible to flood the tunnels or tunnel sections themselves with protective gas and install airlocks at the tunnel entrances and exits. When we speak of "other containers," we mean all container-like and interchangeable or replaceable receptacles that can be used or are conceivable to be used in such systems. This specifically refers to dosing containers for feeding building materials to a coating unit, and overflow containers for collecting excess building materials. However, containers or "modules" can also be used that do not contain "fill" in the broader sense of the word, but rather functional elements, such as service modules that can, for example, automatically change protective glass, or cleaning modules, milling head modules, or measuring head modules that can be used to perform various cleaning, processing, or measuring tasks within the different stations. These modules can, for example, be located in the upper area...The containers or modules can be suspended within the tunnel or tunnel system, whereas construction containers, overflow containers, and dosing containers can advantageously be supported on a track, e.g., rail-like, in the lower section of the tunnel. It is also within the scope of the invention to mount the containers or modules on transport carriages equipped with a self-propelled drive and a control system, e.g., a hall GPS control system. The containers or modules can also be designed with a self-propelled drive, i.e., they can find their way to their correct position in a process-controlled manner. Alternatively, it is possible to provide some type of fixed, integrated push-pull transport system within the tunnel. According to the invention, the travel path within the tunnel can always be kept largely clear. This allows for high-speed, unobstructed container module traffic. For this purpose, the tunnel or tunnel system is equipped with side niches or passing stations into which the movable containers or modules can be inserted, particularly in a working position or during a passing maneuver, to ensure the continuous clearance of the travel path running through the tunnel opening for further containers. For example, a side niche is provided in a process station that accommodates a construction container as well as the dosing and overflow containers in their respective working positions. The actual tunnel travel path is located in front of or behind these niches, and further containers can be sent at relatively high speed through the cleared travel path to other process stations or handling stations in a series. The tunnel or tunnel system can be closed at one end, which improves the possibilities for inert gas flushing. However, it is also possible, for example, to arrange a container depot at one end of the tunnel within an inert gas atmosphere. This depot stores pre-flooded construction containers with pre-installed construction panels, dosing containers, or empty overflow containers, which are then moved into the tunnel or to the respective work positions. From the other end, dosing containers can be moved in, or overflow containers can be moved out and emptied. The tunnel does not necessarily have to have only one entrance or exit; it is equally possible to provide side entrances and exits to allow for short routes to transport containers to their respective work sites or to launch service modules from there, thus minimizing service procedures. Basically, it is possible to set up housing elements separately, so that a tunnel chain is formed in the housing elements, or to connect the housing elements so that a continuous tunnel is formed within the housing elements. It is also possible to install tunnel connecting elements, which can be straight or curved, between the individually installed housing elements of process stations, handling stations, or other stations. Furthermore, the tunnel connecting elements can be designed to be gas-tightly flanged to the housing inlets and outlets, and can be made flexible or equipped with a hinged connection, allowing the plant housing elements to be freely adapted to the layout of a production hall. This means the tunnel connecting elements can be curved to create a non-straight travel path.Container guidance elements that can be coupled to one another or merge into one another are arranged in the individual housing sections and / or tunnel connecting elements; these can be rails or guide elements or the like, as already mentioned above; all elements that can ensure sufficiently precise guidance of containers or modules are included here. In principle, it is also conceivable to provide several parallel tunnels, in the sense of a "twin-tube tunnel," or to provide parallel "opposing lanes" within a single tunnel tube. This simplifies the organization of transport, increases transport speed, and thus reduces transport times within the tunnel. It is also possible to provide a branching tunnel leading to a plurality of process stations or to a plurality of unpacking or handling stations. It is also conceivable to design at least one process station and / or handling station and / or tunnel connection element as a reversing station, so that a reversing loop is formed for container or module transport. In accordance with the method claim, it is intended to ensure that a travel path traversing the majority of housing units of process and handling stations is not blocked by mobile or parked containers, but rather that the travel path is kept largely clear. The travel path can be a one-way path or a two-way path. The invention is explained in more detail with reference to advantageous embodiments in the drawings. These show Fig. 1 a system according to the invention with separately arranged process stations and handling stations and a transport path for containers running through a tunnel through both system components; Fig. 2 a system according to the invention with directly adjacent handling stations and process stations and a tunnel running through them for transporting containers; Fig. 3 a system with one handling station and, for example, three process stations to form a production line with a tunnel arrangement according to the invention; Fig. 4 a schematic representation of a handling station and a process station with tunnels running through both for transporting different containers; Fig. 5 a schematic representation of a system with a handling station and two process stations as well as a container magazine; Fig. 6 a representation according to Fig.5, in which the movement of the different containers is shown; Fig. 7 a representation according to Fig. 1, in which the handling station and the process station are connected by a tunnel extension element; Fig. 8 a schematic top view of a plant with a container magazine, a handling station, two process stations and a reversing station, wherein all stations are connected by tunnel extension elements of different shapes; Fig. 9 a schematic representation of a plant in which three process stations are connected to a handling room according to the tunnel principle. The system 1 shown in the drawings is used for the production of three-dimensional objects 2 by successively solidifying layers of a build material that can be solidified by radiation, in particular laser radiation, at the locations corresponding to the respective cross-section of the object 2. Such a system 1 comprises at least one process station 4 arranged in a first housing 3 for carrying out the layer-by-layer additive manufacturing process in a build container 5, and at least one handling station 7 in a second housing 6 for unpacking the produced objects 2 from the build container 5, which is movable between the process station 4 and the handling station 7. The at least one process station 4 and the at least one handling station 7 are arranged in separate housing units (3, 6) which can be set up separately or individually and which, in the exemplary embodiment, are provided with feed openings 11 in their side wall areas 10 and are designed so that, in a nested or partially separated configuration, they can form at least one continuous tunnel 12 or a tunnel chain, wherein the tunnel 12 or the tunnel chain forms a travel path 13 integrated into the housing units 3, 6 for construction containers 5 and other movable containers. It is common knowledge among those skilled in the art that the housing 3 of the process station 4 must integrate a multitude of devices and equipment necessary for carrying out the process, e.g., radiation sources in the form of at least one laser, at least one scanning system, a process chamber, a dosing chamber, an overflow chamber, and the like. The handling station 7 comprises a glovebox 15 with manual controls so that the unpacking process can be carried out within this glovebox 15. Furthermore, the handling station 7 may include a sieve module by which previously used building material can be freed from clumps and melt residues. Figure 2 shows that the two housings 3, 6 can also be placed directly next to each other. The feed openings 11 arranged in the side wall areas 10 are arranged congruently so that the continuous tunnel 12 and travel path 13 according to the invention can be formed. As can be seen from Fig. 3, a handling station 7 with a housing 6 can also be combined with a plurality of process stations 4, so that a production line is formed. Figure 4 illustrates how individual elements can be arranged within the housings 3 and 6 and how the tunnel 12 running through them is relocated along the travel path 13. It is important to note that the tunnel 12, or the tunnel chain, is provided with side recesses or extensions 16 inside the housing units 3 and 6. These recesses allow the movable containers to be inserted, particularly in a working position or during a maneuvering operation, to ensure the continuous clearance of the travel path 13 within the tunnel 12 for further movable containers. These further movable containers could be an overflow container 20, a dosing container 21, or other modules not shown in detail in the figure, which could be designed as service modules, cleaning modules, or similar components. In the embodiment shown in Figures 1-4, the tunnel 12, and thus also the travel path 13, runs straight through the housing units 3, 6. However, it is equally possible to provide a curved tunnel path, such as can be created by chamfering the side wall areas 10 of the housing units 3, 6, or by tunnel connecting elements 30, which are shown schematically in Figures 7 and 8. The tunnel connecting elements 30 can either be designed as straight connecting boxes through which the tunnel 12 runs, or they can be provided with wedge-shaped inserts 31 to form a curved path for the tunnel connecting elements 30. It is also possible to provide flexible sections 32 in the tunnel connecting elements 30.The end regions 33 of the tunnel connecting elements 30 can be provided with gas-tight flange-like connecting units 34, which can be flanged to the feed openings 11 in the side wall regions 10. In drawing figure 8, a reversing station 40 is indicated; this can be designed similarly to a tunnel section and attached to one end of the resulting tunnel 12. A device resembling a turning loop for the containers or modules to be transported would be conceivable as a reversing station. In principle, it is possible to construct tunnel 12 with two tubes or at least to equip it with two opposing travel paths, so that oncoming traffic is possible in one tunnel tube. Figures 5 and 6 show a container magazine 52, which may be connected to the tunnel arrangement in a gas-tight manner and in which different containers and / or modules can be kept ready for dispatch into the tunnel 12. Figure 9 shows a system 1 in which a plurality of process stations 4.1, 4.2 and 4.3 are arranged in series according to the tunnel concept of the invention, wherein the process stations 4.1, 4.2 and 4.3 are arranged in separate first housings 3 and are connected to each other by tunnel connecting elements 30. On the left side of the drawing, a larger, separate room 50 is shown, which can be designed as a cleanroom, may be fully or partially inertizable, and may even be accessible to an operator. Within this room, a robot 51 can perform preparatory or unpacking steps on the construction container 5, which can be moved into the inertized room 50 via a tunnel connection element. It is also within the scope of the invention to provide such an inertable space 50 solely for the preparation of the construction containers 5 and to arrange a handling station 7 within the housing chain in a further housing, where the components are then simply unpacked. Furthermore, it is possible to provide a container magazine 52 in the inerted space 50, in which, for example, a plurality of prepared construction containers 5 can be stored for the construction process in the process stations 4. Naturally, other containers prepared for the construction process, such as overflow containers 20 or dosing containers 21 or service modules, can also be kept there for their use in the system. REFERENCE MARK LIST 1 Plant 2 Object 3 First housing 4 Process station 5 Construction container 6 Further housing 7 Handling station 10 Side wall area 11 Feed opening 12 Tunnel 13 Travel path 15 Glovebox 16 Extension 20 Overflow container 21 Dosing container 30 Tunnel connecting element 31 Insert 32 Flexible section 33 End area of ​​30 34 Connecting unit 40 Reversing station 50 Room 51 Robot 52 Container magazine

Claims

A system (1) for producing three-dimensional objects (2) by successively solidifying layers of a radiation-hardenable build material at the locations corresponding to the respective cross-section of the object (2), wherein the system (1) comprises a plurality of individual housing units (3, 6) that can be set up at a distance from one another and includes at least one process station (4) for carrying out an additive manufacturing process and at least one handling station (7) for unpacking manufactured objects (2) from a construction container (5) movable between the process station (4) and the handling station (7), characterized by a tunnel chain comprising: one or more feed openings (11) which are configured to introduce several movable construction containers (5) into the tunnel chain, several tunnel sections which are integrated in separate housing units (3, 6) that can be set up separately or individually, wherein the housing units (3,6) at least one process station (4) and / or at least one handling station (7) is arranged, wherein the several tunnel sections together form a continuous tunnel, a travel path (13) for construction containers (5) and other containers or modules movable within the system, along which the movable construction containers (5) can be moved through the tunnel formed by the tunnel sections, wherein the tunnel (12) or the tunnel chain is provided in the interior of the housing units (3, 6) with side niches or extensions (16) into which the movable containers can be driven during a maneuvering operation to allow the continuous opening of the travel path (13) running in the tunnel (12) for other movable containers. The system according to claim 1, characterized in that the tunnel (12) or the tunnel chain is provided in the interior of the housing units (3, 6) with side niches or extensions (16) into which the movable containers can be inserted in a working position to continuously release the travel path (13) running in the tunnel (12) for further movable containers. A system according to one of the preceding claims, characterized in that the tunnel (12) or the tunnel chain is closed at one end. Plant according to one of the preceding claims, characterized in that the tunnel (12) or the tunnel chain can be flooded with protective gas. Plant according to one of the preceding claims, characterized in that protective gas locks are arranged between the individual housing units (3, 6) or tunnel chain elements. System according to one of the preceding claims, characterized in that tunnel connecting elements (30) are arranged between the housing units (3, 6). A system according to one of the preceding claims, characterized in that the tunnel (12) passing through the housing units (3, 6) is straight. The system according to claim 6, characterized in that the tunnel connecting elements (30) are curved to form a non-straight travel path (13). System according to claim 6 or 8, characterized in that container guide elements that can be coupled to one another or merge into one another are arranged in the individual housing sections (3, 6) and / or tunnel connecting elements (30). System according to one of the preceding claims, characterized in that at least one service module and / or one protective glass replacement module and / or one cleaning module and / or one milling head module and / or one measuring head module is movable in the tunnel (12). The system according to claim 10, characterized in that the modules are movable in an upper area of ​​the tunnel (12) or the tunnel chain. A system according to one of claims 6, 8 or 9, characterized in that a plurality of tunnels (12) arranged at least in sections parallel are arranged within the housing units (3, 6) and / or within the tunnel connecting elements (30). A system according to one of claims 6, 8, 9 or 12, characterized in that at least one tunnel escape niche is arranged within the tunnel connecting elements (30). Plant according to one of the preceding claims, characterized in that at least one tunnel (12) branches into a plurality of tunnel sections and leads at least from one process station (4) to a plurality of handling stations (7). Plant according to one of claims 6, 8, 9, 12 or 13, characterized in that at least one process station (4) or one handling station (7) or one tunnel connecting element (30) is designed as a reversing station. Method for producing three-dimensional objects (2) by successively solidifying layers of a build-up material that can be solidified by radiation at the locations corresponding to the respective cross-section of the object (2), with the following features: - Provision of a system (1) with a plurality of individual housing units (3, 6) that can be set up at a distance from one another and that comprise at least one process station (4) for carrying out the additive manufacturing process and at least one handling station (7) for unpacking manufactured objects (2) from a construction container (5) that can be moved between the process station (4) and the handling station (7), characterized by - Provision of a tunnel (12) passing through the plurality of housing units (3, 6) as a travel path (13) for the construction containers (5) and further containers or modules and design of the tunnel (12) such that in the working position or during an avoidance operation in the housing units (3,6) Arranged construction containers (5) or other movable containers do not block the travel path (13) through the tunnel (12), wherein the further movable containers comprise at least one metering container (21) for supplying the construction material to a coating device and / or an overflow container (20) for receiving excess construction material from the coating device, wherein the tunnel (12) or the tunnel chain is provided in the interior of the housing units (3, 6) with side niches or extensions (16) into which the movable containers can be driven during a maneuvering operation to continuously clear the travel path (13) running in the tunnel (12) for further movable containers. Method according to claim 16, characterized in that the travel path (13) is designed as a one-way travel path. Method according to claim 16, characterized in that the travel path (13) is designed as a two-way travel path.

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