Management system for managing a modeling device, monitoring device and method therefor

Abstract

System, comprising: a monitoring device configured to monitor a modeling device (102) configured to form a three-dimensional object (405, 414); and a management system (106) configured to communicate with the monitoring device via a network (108); wherein the monitoring device contains: a detection device (306) for detecting a number of layers recorded in a storage unit (204) of the modeling device, a generating device (307) for generating a message containing identification information for identifying the modeling device and the detected number of layers, and a transmission device (301) for transmitting the message generated by the generation device to the management system, and where the management system includes: a receiving device (351) for receiving the message from the monitoring device, and a storage device (359) for storing the identification information and number of layers contained in the received message in a memory (254), characterized in that the number of layers detected by the detecting means indicates a total number of layers in the mold processing of the plurality of three-dimensional objects corresponding to a plurality of orders by a molding means (209) of the modeling apparatus.

Description

BACKGROUND OF THE INVENTIONField of the invention

[0001] The present invention relates to a mechanism of a management system for managing a modeling device using network communication. Description of the state of the art

[0002] Previously, systems existed that collected operational information about image forming devices for forming an image on a sheet, such as a printing device and a copying machine, via a network and performed maintenance work. For example, JP 2003-159854 A discusses a method for receiving a notification of the remaining stock of a consumable, such as toner, from an image forming device in order to perform inventory management of the consumable. To increase the accuracy of inventory management, the method discussed in JP 2003-159854 A utilizes a total counter value included in the notification of the remaining stock. The total counter value indicates the cumulative number of printed sheets since the image forming device started operating.According to JP 2003-159 854 A, an administrative or management system can appropriately determine an operating amount of the image forming apparatus within a specific period of time by referring to a change in the value of the total counter.

[0003] Modeling devices, such as three-dimensional (3D) object forming devices (so-called 3D printers) for forming 3D objects, have become widespread in recent years. The above management system can be used in the future to perform maintenance work on modeling devices in a network.

[0004] There are various modeling methods that can be used by 3D printers, and the objects that can be created by 3D printers also vary, so it may be difficult to adequately identify the operating states of the modeling devices by a management system via a network at a remote location. Under current circumstances, the values of the total counters of the 3D printers, which are cumulatively counted to meaningfully reflect the operating states regardless of which modeling processing is executed within a specific period of time, cannot be collected, and the count values are equivalent to the number of printed sheets according to the conventional method.JP 2003-340925 A proposes a sales management server that receives processing data of a molded product, calculates the weight of the powder material required for production, and determines the powder material while taking costs into account. WO 2016 / 032544 A1 relates to a system for managing the creation of a 3D object by an additive manufacturing system. DISCLOSURE OF THE INVENTION

[0005] The present invention is directed to a mechanism for collecting new information for appropriately identifying an operation status over a network from a modeling device which is a management target of a management system.

[0006] According to one aspect of the present invention, a system according to claim 1 and a monitoring device according to claim 6, corresponding methods according to claims 5 and 15 and a corresponding computer-readable storage medium according to claim 17 are provided.

[0007] Further features of the present invention will become apparent from the following description of exemplary embodiments with reference to the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 is a diagram illustrating a configuration example of a network system including a modeling apparatus and a management system according to an embodiment of the invention. Fig. 2A and Fig. 2B are diagrams illustrating examples of hardware configuration of the devices constituting the network system according to the exemplary embodiment of the invention. Fig. 3A and Fig. 3B are diagrams illustrating examples of a software module configuration of the devices constituting the network system according to the embodiment of the present invention. Fig. 4A and Fig. 4B are diagrams illustrating examples of a modeling method according to the embodiment of the invention. Fig. 5A and Fig. 5B are flowcharts illustrating the transmission processing of operation information via the modeling device. Fig. 6 is a flowchart illustrating the reception processing of the operation information by the management system. Fig. Figure 7 is a flowchart illustrating the processing for calculating an average lifetime of each type of consumable. Fig. 8 is a flowchart illustrating the processing by which a monitoring device transmits information about details of modeling processing. DESCRIPTION OF THE EXAMPLES OF WORK

[0008] An embodiment of the present invention will be described below with reference to the drawings.

[0009] Fig. 1 is a diagram illustrating a configuration example of a network system including a modeling device (a three-dimensional (3D) object molding device) and a management system according to an exemplary embodiment of the invention.

[0010] In Fig. 1, a modeling device 102 is a device for molding a 3D object based on model data. A firewall 104 is used to increase the security of an intranet. A personal computer (PC) 105 is used by a general user for work. The modeling device 102, a proxy server 103, the firewall 104, and the PC 105 are connected to each other via a local area network (LAN) 101. The PC 105 can send model data for a 3D object to be molded to the modeling device 102. Fig. 1, an installation environment 107 of the modeling device 102 includes an intranet that includes the proxy server 103 and the firewall 104. Multiple modeling devices may be installed in the intranet.

[0011] A management system 106 is a system for managing one or more modeling devices. The management system 106 communicates with the devices in the installation environment 107 via the Internet 108. The management system 106 includes one or more server computers. The management system 106 primarily collects operational information regarding the modeling device 102 and provides management services based on the operational information. Examples of the management services include performing maintenance work on the modeling device 102 and generating reports.

[0012] The modeling device 102 includes a built-in monitoring device, which in turn has the function of transmitting device information and operational information to the management system 106. The device information includes individual identification information and model information about the device itself. The operational information includes fault information and status information.

[0013] The monitoring device, which includes the function of transmitting device information and operation information about the modeling device 102, may be installed on the LAN 101 separately from the modeling device 102. In this case, the monitoring device may receive device information and operation information from one or more modeling devices located in the LAN 101 and transmit the received information to the management system 106.

[0014] In the present embodiment, it is assumed that communication protocols between the monitoring device and the management system 106 are, for example and without limitation, protocols such as Hyper Text Transfer Protocol (http) and http-Secure (https). Various communication protocols may be used, such as WebSocket and Simple Mail Transfer Protocol (SMTP).

[0015] Fig. 2A and Fig. 2B are diagrams illustrating examples of hardware configuration of the devices constituting the network system according to the embodiment of the present invention.

[0016] Fig. 2A illustrates an example of a hardware configuration of the modeling device 102. A central processing unit (CPU) 201 executes programs stored in a read-only memory (ROM) 203 and a memory 204 to centrally control devices via an internal bus 206. A random access memory (RAM) 202 functions as memory and a work area for the CPU 201. Pre-installed programs and data are stored in the ROM 203. The ROM 203 also stores individual identification information, model information, and destination information. The destination information indicates a zone for which the modeling device 102 is shipped. A language displayed on the input / output device 201 is determined according to the destination information. A network interface (I / F) 205 is used to exchange data unidirectionally or bidirectionally with an external network device or the PC 105 via the LAN 101.

[0017] The memory 204 functions as an external storage device. The memory 204 stores modeling data. The memory 204 can store operation information detected and recorded inside the modeling device 102, as well as information about consumables, instead of the RAM 202. The memory 204 also stores a program for implementing the function of the monitoring device. The operation information includes fault information, status information, and log information. The operation information stored in the memory 204 is obtained from the monitoring device and sent to the management system 106 via a network such as the Internet 108.

[0018] The operating unit 208 represents a configuration responsible for input and output to and from the modeling device 102. In particular, the operating unit 208 accepts inputs (such as keystrokes) from users and sends signals corresponding to the inputs to the processing units described above via an operating unit I / F 207. The operating unit 208 further includes a display device (such as a touch panel) for providing required information to users and for accepting user actions.

[0019] A modeling unit (a 3D object molding device) 209 includes a modeling stage for layering modeling materials on the top or bottom surface of an object to be molded in the form of a layer or sheet to form a 3D object, and a configuration for applying effects and finishes to the object and for molding support portions. The modeling processing (a 3D object molding processing) performed by the modeling unit 209 is referred to herein as an additive manufacturing method. Additive manufacturing is performed by using modeling commands (molding commands) on section shape data in units of layered surfaces (i.e., slice data) generated from model data from a 3D modeling application installed in the PC 105. An internal configuration of the modeling unit 209 includes a hardware configuration depending on the modeling method supported by the modeling device 102.Examples of the modeling method to which an exemplary embodiment of the invention is applicable are described below with reference to . Fig. 4A and Fig. 4B.

[0020] A consumables replenishing unit 212 supplies consumables, including a modeling material 213 required for molding an object, to the modeling unit 209. When the modeling device 102 employs a modeling method in which support portions are formed when molding an object, the consumables replenishing unit 212 also supplies support materials stored therein as consumables to the modeling unit 209. There are various types of modeling materials 213. Examples include photocurable resin (photopolymer), thermoplastics, metal powder, and gypsum mortar. Examples of the photocurable resin include liquid resins that harden upon irradiation with ultraviolet rays.

[0021] The consumables replenishing unit 212 can manage the amounts of the modeling material 213 and the support materials supplied to the modeling unit 209. The supplied amounts can be recorded as a log in the memory 204. The supply amounts for one object (one order or job) are recorded in a log record. The log can also be recorded by a method other than on an object-by-object basis. For example, the supply amounts can be recorded within a predetermined period of time. When the modeling device 102 can perform color modeling in multiple colors, the consumables replenishing unit 212 can supply the modeling materials 213 of the respective multiple colors to the modeling unit 209 and manage the supply amounts separately. The supply amounts can be recorded as a log in the memory 204.

[0022] To supply the consumables to the consumable refill unit 212, bottles containing the modeling material 213 and other consumables in liquid or powder form can be attached to the consumable refill unit 212. The consumables can be manually supplied to the consumable refill unit 212 using special bottles.

[0023] Several sensors 215 for different purposes are arranged inside the modeling device 102. Some of the main examples of the sensors 215 inside the modeling device 102 are described here.

[0024] Some sensors detect the supply amounts of the consumables managed by the consumables replenishing unit 212 and supplied to the modeling unit 209, and detect the remaining amounts of the consumables stored in the consumables replenishing unit 212. A sensor that detects the attachment of a bottle containing the modeling material 213 and detects identification information about the bottle may be arranged inside the modeling device 102. A sensor that detects an abnormal temperature or a malfunction inside the modeling unit 209 is arranged therein. If the modeling unit 209 includes a modeling head and a stage for modeling processing, sensors for counting the number of times these elements are driven (the number of movement strokes) are also arranged.

[0025] Further examples include a sensor that counts, as layer counter information, the number of surfaces of the modeling material 213 actually layered by the modeling unit 209. When the modeling device 102 and the modeling unit 209 are operating normally, the number of layered surfaces approximately matches the number of blocks of slice data corresponding to the modeling data used in the modeling processing executed by the modeling unit 201. In fact, some slice data or layer data may be left unused in the modeling processing due to factors such as a malfunction. The layering processing may be executed for maintenance purposes. Therefore, the said number of layered surfaces counted by the sensor and the total number of blocks of slice data within the same period of time may not match each other.

[0026] The sensors mentioned above have been explained as being implemented in hardware. However, the sensors can be partially or entirely replaced by software sensors with equivalent detection functions.

[0027] The modeling apparatus 102 includes optional devices such as auxiliary equipment required for some modeling methods and peripheral devices (not shown) to enhance the functions and mechanisms of a 3D printer. Examples of the auxiliary equipment include a device for resolving performance issues when using an inkjet method and a cleaning device required when using a stereolithography method (a stereolithography apparatus (SLA)). Examples of the peripheral devices include a camera and an integrated circuit card (IC card) reader.

[0028] Fig. 2B is a diagram illustrating a hardware configuration as an example of an information processing device. Examples of the information processing device include the PC 105 and one or more server computers that constitute the management system 106 according to the embodiment of the invention. Furthermore, when the monitoring device is installed outside the modeling device 102, the monitoring device includes a configuration similar to that found in the illustrated information processing device. The program for implementing the function of the monitoring device is then executed within the information processing device.

[0029] A CPU 251 executes programs stored in a ROM 253 and a memory 254 to control the entire information processing device via an internal bus 256. The ROM 253 and the memory 254 also store various types of data other than the programs. For example, the memory 254 can store device information and operational information regarding the modeling device 102. A RAM 252 functions as storage and work area for the CPU 251. Examples of an input / output I / F 257 include a Personal System / 2 (PS / 2), a Universal Serial Bus (USB), and analog and digital display I / F. An input / output device 258 includes a keyboard, a mouse, a cathode ray tube (CR), and / or a liquid crystal display. The input / output device 258 can be connected to the information processing device via the input / output I / F 257.The information processing device performs communication via the LAN 101 and the Internet 108 by means of a network interface (I / F) 255.

[0030] Fig. 3A and Fig. 3B are diagrams illustrating examples of software module configurations of the devices constituting the network system according to the exemplary embodiment of the invention. Such configurations represent virtual modules serving as main components implemented by executing programs according to the exemplary embodiment of the invention. The illustrated configurations are merely examples; various module configurations may be used as long as the processing described below can be implemented.

[0031] Fig. 3A is a diagram for describing a software module configuration of the modeling device 102.

[0032] A communication unit 301 communicates with external devices, such as the management system 106, via the network interface (I / F) 205. A storage unit 302 records operational information detected by the hardware or software sensors primarily in the memory 204. The storage unit 203 also records the device information about the modeling device 102 in the memory 204. The device information includes the individual identification information and model information regarding the modeling device 102, vendor information indicating a manufacturer, and communication information such as an Internet Protocol (IP) address and a Media Access Control (MAC) address.

[0033] A modeling management unit 303 performs modeling control in accordance with modeling commands to the modeling unit 209, and also performs control for supplying consumables to the consumable replenishing unit 212. An operation unit 304 accepts operations of the modeling device 102, including the user's commands for executing modeling.

[0034] A device information management unit 305, a monitoring unit 306, a generating unit 307, and a communication control unit 308 are module configurations corresponding to the functions of the monitoring device.

[0035] The device information management unit 305 manages the device information relating to the modeling device 102 to be monitored using the memory 204. The monitoring unit 306 monitors a state of the modeling device 102. Specifically, the monitoring unit 306 implements a monitoring function of referring to the operational information recorded in the memory 204 of the modeling device 102 and determining whether there is information to be reported as an event (such as the occurrence of a failure or recovery from a failure). The monitoring unit 306 also determines whether a notification of a consumable needs to be made. The monitoring unit 306 accepts and reflects monitoring settings such as a data transmission plan and a monitoring target event from the management system 106, received via the communication unit 301.The generation unit 307 generates messages such as an alarm or a service call, including message contents specified as messages that must be reported by the monitoring unit 306. The generation unit 307 also generates a message containing operational information to be regularly transmitted from the monitoring device to the management system 106. The communication control unit 308 causes the communication unit 301 to transmit the messages generated by the generation unit 307 using a predetermined communication protocol.

[0036] When the monitoring device is located outside the modeling device 102, the modules corresponding to the functions of the memory 204 in the modeling device 102 and the monitoring device exchange data over a network using a predetermined protocol (such as the Simple Network Management Protocol (SNMP) and the Internet Printing Protocol (IPP)). The communication control unit 308 transmits the messages using the network I / F 255 of the monitoring device.

[0037] Fig. 3B is a diagram illustrating a software module configuration of the management system 106.

[0038] A communication unit 351 includes a function for communicating with external devices such as the modeling device 102 and the monitoring device using the network I / F 255. Specifically, the communication unit 351 accepts a message containing device information and operational information about the modeling device 102 via the monitoring device. The communication unit 351 also controls the transmission of a message containing the monitoring settings of the monitoring device.

[0039] A display control unit 351 provides screen information for displaying the device information and operational information stored in memory 254 or in a storage service (not shown) on the network via a web browser. A World Wide Web (WWW) server program runs on management system 106, allowing the device information to be retrieved from any PC by a service person of a sales company.

[0040] A command analysis unit 354 analyzes data received from an external device and determines message contents included in the data. A message generation unit 355 generates messages containing notifications and monitoring settings generated by a device management unit 356, as well as responses to requests from the modeling device 101 and the monitoring device.

[0041] The device management unit 356 is a configuration implemented by executing a special program for managing the modeling device 102 to be managed.

[0042] A notification management unit 357 specifies a notification destination (such as the monitoring device and the sales company) and generates required notification information. Examples of the generated notification include a maintenance request notification to a service person for the modeling device 102 and a replenishment request notification for consumables.

[0043] A distributor information management unit 358 manages information concerning the distributor that performs maintenance of the modeling device 102 to be managed, manages consumables, and arranges delivery. The distributor information is stored in the memory 254 or in the unillustrated storage service on the network.

[0044] A device information management unit 359 manages device information about the modeling device 102 to be managed and the monitoring device using the storage 254 or the unillustrated storage service on the network. Examples of the device information to be managed include the unique identification information of the modeling device 102, information about models and manufacturers, and communication information such as an IP address. The device information management unit 359 also manages an operation status (status) including an error and an alarm of the notification device 102 based on message contents from the monitoring device. Information for searching the status of the modeling device 102 managed by the device information management unit 359 is provided on the network in real time via the www server program.This information is sought by dispatchers and service personnel of the operating company. The device information management unit 359 also manages fault information, which indicates statuses such as "unprocessed," "in progress," and "processed" according to the handling status by the distribution company.

[0045] A customer information management unit manages information about a customer who owns the modeling device 102 to be managed. The information also includes information about a maintenance contract with the sales company. The maintenance contract covers maintenance agreements with each customer. Examples include the regular delivery of consumables to the installation environment 107 of the modeling device 102, regular maintenance work, and the handling of a failure event.

[0046] A consumable inventory management unit 361 manages the quantities of consumables, such as consumables of the modeling device 102 and replacement components of the modeling device 102, stored by the customer. The consumables whose inventory is to be managed can be managed by consumable IDs. When the inventory quantities meet a predetermined condition, a delivery request is automatically sent to the service person via email.

[0047] Specifically, inventory levels can be managed based on messages indicating the remaining amounts of consumables in the modeling device 102 and messages containing information indicating the wear rates of components. These messages are sent from the monitoring device. The contents of the sent messages vary depending on the model of the modeling device 102. Some devices can send a message indicating the consumption amount of a consumable. Some can send a message containing information indicating identification information regarding a replacement time of a consumable or the consumption data before and after replacement.

[0048] A master information management unit 362 manages master information. The master information is required to display model information, failure information, and / or consumable information via the WWW server program, or to perform determination processing to be described below. Examples of the master information include registration information regarding specifications, such as a product name corresponding to a specific model, useful consumable information, and performance information. In other words, the performance of the modeling device 101 (modeling methods and types of consumables and consumable components used) can be identified based on the information contained in the message from the monitoring device, such as the model of the modeling device 102.The master information to be managed also contains information about a location of the modeling device 102.

[0049] A consumable life management unit 363 manages a history of the lifetimes of the actually used consumables based on exchange information about the consumables of the modeling device 102, which is transmitted via the monitoring device. Based on the history, the average lifetimes of the consumables during current operation can be calculated.

[0050] A command management unit 354 generates and manages commands for transmission to the monitoring device. The generated commands are sent to the monitoring device via the communication unit 351. Examples of the commands include commands for changing the transmission plan to the management system 106, changing the event type to be reported, updating firmware, and rebooting. The command management unit 364 manages the results of the command execution as statuses such as "success," "fail," and "unknown."

[0051] A firmware information management unit 365 manages firmware vision information about the modeling device 102. The firmware information management unit 365 performs firmware distribution settings in cooperation with a firmware management system (not shown). The firmware management system distributes the firmware according to the distribution settings.

[0052] Fig. 4A and Fig. 4B show examples of modeling methods for performing additive manufacturing in which the exemplary embodiment of the invention can be applied. Modeling devices 102 that support the modeling methods of the examples described below can be managed by the management system 106.

[0053] Fig. 4A is a diagram illustrating a first example of a method for forming an object by material layer lamination.

[0054] In this method, the layering of a material layer 402 on a stage 406 and the irradiation of energy 407 (such as light, heat and ultraviolet rays) from an energy source 401 are repeated in the modeling unit 209 for additive manufacturing.

[0055] A material layer 402 includes a modeling material 404, which actually constitutes the object, and a support material 403. The modeling material 404 is welded to a laminated object 405 (hereinafter "the object 405") using energy 407 (such as light, heat, and ultraviolet rays). The support material 403 is not welded to the object 405 and prevents the object 405 from collapsing. For example, the support material 403 is soluble in water. When the object 405 is removed, the support material 403 can be removed from the object 405 using water.

[0056] The modeling management unit 303 records the number of times the material layer 402 is stacked (the number of stacked layers) cumulatively counted after the start of use of the modeling device 102, and stores the number of times the material layer 402 is stacked in the memory 204 as layer count information. Details will be described below. According to the exemplary embodiment of the present invention, the number of times the material layer 402 is stacked, counted during multiple 3D object shape processing performed by the modeling device since the start of use of the modeling device, is used as an index for finding a general operating status of the modeling device 102. The recorded number of times the material layer 402 is then transmitted to the management system 106 via the monitoring device as the total count value of the modeling device 102.

[0057] The modeling management unit 303 can record and store the layering frequency in units for each object or job in the memory 204, in addition to the layering frequency cumulatively counted since the modeling device was started to be used. Information similar to this operational information, as described herein, includes information on the amount of modeling material 404 supplied to the modeling unit 209 until the object 405 is completed, and the volume of the object 405 calculated based on the modeling data (model data). This information is also transmitted via the monitoring device to the management system 116 for reporting purposes.

[0058] A second example of the additive manufacturing method is a stereolithographic process (not shown).

[0059] In this process, three steps are repeated to gradually create the 3D object: (1) stacking (piling) a layered modeling material (such as an ultraviolet-curing resin) on a horizontal surface of a stage, (2) irradiating energy (such as ultraviolet rays) to areas where the modeling material is to be cured using a laser, and (3) lowering the stage. Areas not exposed to ultraviolet rays remain uncured and remain on the stage. The uncured modeling material serves as support areas to prevent the laminated object from collapsing. When the modeling processing is completed, the support areas are removed, so that only the laminated object can be taken out.

[0060] The modeling management unit 303 records the layering frequency of the modeling material on the stage since the start of use of the modeling device 102 and stores the layering frequency in the memory 204 as layer count information. Also in this modeling method, the layering frequency cumulatively counted since the start of use of the modeling device is used as an index to identify a general operating status of the modeling device 102. The recorded number of layerings is then transmitted to the management system 106 via the monitoring device as the value for the total count of the modeling device 102.

[0061] The modeling management unit 303 records operational information from which the usage scope of the modeling material for each object can be derived and stores the operational information in the memory 204. Examples of such operational information include the volume of the laminated object calculated based on the modeling data. The stored operational information is also sent to the management system 106 via the monitoring device.

[0062] Fig. Figure 4B is a diagram illustrating a third example of a method for forming an object, here using an inkjet process.

[0063] The modeling unit 209 forms an object on a stage 417 using an inkjet head 409. The inkjet head 409 includes a modeling material nozzle 410, a support material nozzle 411, a power source 412, and a rotary cutter 413. The power source 412 emits energy to harden the modeling material. The rotary cutter 413 adjusts the thickness of the object through additive manufacturing.

[0064] In this method, three steps are repeatedly performed to gradually generate the 3D object: (1) ejecting fine particles from the modeling material nozzle 410 and the support material nozzle 411 to form a layer, (2) irradiating energy from the energy source 412, and (3) lowering the stage 417. The positions at which the modeling material nozzle 410 and the support material nozzle 411 eject particles are determined by coordinates specified by pieces of slice or layer data based on the respective modeling commands. Support regions 415, which are formed by curing the particles ejected from the support material nozzle 410 to prevent collapse of an object 414, can be removed after modeling.The ejection of fine particles from the modeling material nozzle 410 and the support material nozzle 411 is followed by a step of scraping the surface formed from the ejected particles with the rotary cutter 413 to adjust the thickness of the surface.

[0065] In this method, the stage 417 is lowered the number of times equal to the number of stacked surfaces. Therefore, the frequency of lowering the stage 417 during 3D object shape processing can be treated as the frequency of stacking. The modeling management unit 303 records the frequency of stacking starting from the start of use of the modeling device 102 and stores the frequency of stacking in the memory 204 as layer count information. The recorded frequency of stacking is transmitted to the management system 106 via the monitoring device as the total count value of the modeling device 102 when using the inkjet method.

[0066] The modeling management unit 303 can treat the frequency of ejection by the modeling material nozzle 410 and the support material nozzle 411 as operational information for identifying the wear rates of the respective nozzles. Therefore, the modeling management unit 303 also stores this information in the memory 204. The stored information is then transmitted to the management system 106 via the monitoring device. Other operational information, from which the usage amount of the modeling material for each object can be determined, is also stored in the memory 204 and then transmitted to the management system 106 via the monitoring device. Examples of such operational information include the volume of the laminated object, which is calculated from the modeling data (model data).

[0067] A fourth example of the additive manufacturing method is a modeling process called fused deposition modeling (FDM) (not shown).

[0068] The modeling unit 209 includes a stage and a modeling head for extruding a thermoplastic modeling material molten into a semi-liquid form. The modeling head stacks layers of the modeling material on the stage based on multiple pieces of layer data.

[0069] The modeling head is initially reciprocated in the X-axis direction (hereinafter referred to as the main scanning direction) to deposit a line of modeling material. This operation is repeated while the modeling head is sequentially reciprocated in the Y-axis direction (hereinafter referred to as the sub-scanning direction), thereby depositing a layer of the cross-sectional shape. The modeling head is controlled to move only within the range for which cross-sectional shape data of the object exists on the stage and to extrude the modeling material. After extrusion forming according to a piece of layer data is completed, the modeling head is moved upward in the direction (Z-axis direction) perpendicular to the horizontal surface of the stage. The modeling head then performs extrusion forming according to the next block of layer data.

[0070] In this method, the modeling head moves upward in the Z-axis direction the number of times equal to the number of stacked faces. The number of upward movements of the modeling head in the Z-axis direction during 3D object shape processing can thus be treated as the stacking frequency. The modeling management unit 303 records the stacking frequency starting from the start of use of the modeling device 102 and stores the stacking frequency in the memory 204 as layer count information. The recorded stacking frequency is transmitted to the management system 106 as the total count value of the modeling device 202 using the FDM method via the monitoring device.

[0071] The amount of modeling material extruded from the modeling head can be treated as operational information for determining the wear rate of the modeling head. Therefore, the modeling management unit 303 stores this information in the memory 204. The stored information is transmitted to the management system 106 via the monitoring device. Operational information from which the amount of modeling material used for each object can be determined is also stored in the memory 204 and then transmitted to the management system 106 via the monitoring device. Examples of such operational information include the volume of the laminated object and the extruded amount of modeling material calculated from the modeling data (model data).

[0072] Fig. 5A and Fig. 5B are flowcharts illustrating transmission processing for operation information related to the modeling device 102, which is performed by the monitoring device. The processing is performed by executing a program for implementing the monitoring device by the CPU included in the modeling device 102 or the information processing device on which the monitoring device is running.

[0073] To start management, the monitoring device performs a communication test to check whether communication with the management system 106 is possible. The monitoring device performs the communication test when instructed by a service person of the sales company via the operation unit 208. If the communication test is successful, the types of operation information to be collected and a regular transmission schedule are transmitted from the management system 106.

[0074] Fig. 5A is a flowchart for describing the regular transmission processing of the operation information regarding the modeling device 102 executed by the monitoring device.

[0075] In step S501, the monitoring unit 306 detects a transmission time for each piece of operation information to be collected by the management system 106.

[0076] In step S502, the monitoring unit 306 acquires the intended operating information from the memory 204 of the modeling device 102. The generating unit 307 generates a message containing the operating information received from the monitoring unit 306 and the device information about the modeling device 102.

[0077] In step S503, the communication control unit 308 performs control to send the generated message containing the operation information to the management system 106 via the network.

[0078] Examples of the operational information to be collected by the management system 106 include the layering frequency of the modeling unit 209, which is recorded as the layer count information. For the regular transmission of the layering frequency as a total count value, the generation unit 307 generates a message in step S502 that includes information about the year, month, date, and time of acquisition, as well as the value of the recorded layering frequency, as well as device information such as individual identification information, model information, and communication information. Such regular transmission is performed, for example, once a day at a specified time.

[0079] Fig. 5B is a flowchart illustrating the transmission processing for the operational information representing a fault event occurring in the modeling device 102 (event transmission processing) performed by the monitoring device. The operational information for the monitoring device to be transmitted through the event transmission within the scope of the pieces of operational information to be collected specified by the management system 106 has been specified in advance as a monitoring target.

[0080] In step S551, the monitoring unit 306 detects the occurrence of the event representing the operational information to be monitored, specified by the management unit 106. Specifically, the monitoring unit 306 monitors the operational information recorded in the memory 204 of the modeling device 102. If the operational information serving as the monitoring target is found to be recorded, the monitoring unit 306 detects the occurrence of the event. The sensors of the modeling device 102 can be configured to report the occurrence of the event to the monitoring unit 306.

[0081] Examples of the operational information serving as the monitoring target include an error about a malfunction or an abnormality, as well as a call indicating a maintenance request from the user. Information about the replenishment of a consumable is also included. Identification codes are assigned to these information blocks. A code may include a subcode indicating the location of occurrence when a malfunction or the like occurs in the modeling device 102.

[0082] In step S552, the generating unit 307 generates a message including a code representing the event that occurred, information about the year, month, date and time of occurrence, the value of the layering frequency as the total count value at the time of occurrence, and the device information such as the individual identification information, the model information, and the communication information.

[0083] In step S553, the communication control unit 308 performs control to send the generated message to the management system 106 via the network.

[0084] In the case of event transmission of information about the replacement of a consumable, the generated message further includes a name, an identifier (ID), a serial number of the consumable, information about a wear rate, and the date and time of the previous replacement, in addition to the above information. In the case of replacement of a consumable containing a consumable, the message includes the consumption amount or the remaining amount of the consumable (the modeling material) as information related to the wear rate. In the case of the modeling head of the modeling unit 209, which is an example of a replaceable or replaceable consumable, the message includes the ejection frequency and the extruded amount of the modeling material as information indicating the wear rate.

[0085] Fig. 6 is a flowchart illustrating the reception processing for operation information by the management system 106. This processing is implemented by executing a program by the CPU 251 of the server computer constituting the management system 106.

[0086] In step S601, the communication unit 351 receives a message from an external device or the monitoring device in the present embodiment. In step S602, the device information management unit 359 determines whether a device indicated by the device information in the message is a device to be managed based on the result of message analysis by the command analysis unit 354. If the modeling device 102 is not a device to be managed (NO in step S602), the processing proceeds to step S603. In step S603, the device information management unit 359 discards the received message. This ends the processing. If the modeling device 102 is a device to be managed (YES in step S602), the processing proceeds to step S604.In step S604, the device information management unit 359 stores the operational information contained in the received message in the memory 254 or a storage service (not shown) on the network. The memory 254 or the storage service stores and manages the operational information and information such as the date and time of acquisition in association with the unique identification information of the modeling device 102.

[0087] In step S605, the device information management unit 359 determines whether the received message was transmitted by event transmission. If the received message was transmitted by event transmission (YES in step S605), the processing proceeds to step S606. If the received message was not transmitted by event transmission (NO in step S605), the processing is completed.

[0088] In step S606, the device information management unit 359 determines whether the contents of the received message indicate a consumable replacement event. The device information management unit 359 makes this determination by referring to the code included in the message. If the contents of the received message indicate a consumable replacement event (YES in step S606), processing proceeds to step S607. If the contents of the received message do not indicate a consumable replacement event (NO in step S606), processing proceeds to step S609.

[0089] In step S607, the device management unit 356 determines whether the consumable to be replaced is a target of inventory management by the consumable inventory management unit 361 based on the ID of the consumable (consumable material) included in the received message. If the consumable is found to be a target of inventory management (YES in step S607), processing proceeds to step S608. If the consumable is not found to be a target of inventory management (NO in step S607), processing proceeds to step S609. In step S608, the consumable inventory management unit 361 subtracts "one" from the remaining stock count of the consumable identified by the ID of the consumable.When the quantity of the stock after the subtraction operation satisfies a predetermined condition, the notification management unit 357 automatically issues an email to request the service person to deliver the consumable in question.

[0090] In step S609, the device information management unit 359 executes processing regarding the details of the event that occurred and corresponds to the code contained in the received message. In the notification processing, the device information management unit 359 delivers contents including the device information about the modeling device 102, the details of the event that occurred, the time of occurrence, and the accumulation frequency indicating the total count at the time of occurrence, via the www server program over the network. The service person can check this event information in real time using a web browser.If the event occurred is a malfunction or a service call, the notification management unit 357 automatically sends an email containing the details of the event to an email address of the service person for the modeling device 102 in which the event occurred, as notification processing. The email contains information such as device information about the modeling device 102, the time of the event occurrence, and the loading frequency indicating the total count at the time of the occurrence.

[0091] The message received in step S601 may indicate that an event of the same content is continuously occurring from the same modeling device 102. In this case, in step S609, the device information management unit 359 suppresses notification processing if a predetermined condition is met. Specifically, if a value indicating a difference between the layering frequency in the message now received in step S601 and the layering frequency in the message regarding the previous occurrence of the event is smaller than a threshold value, the device information management unit 359 suppresses notification processing regarding the message now received in step S601. The reason for this is that the same error may have been detected more than once due to faulty operation of the sensors.By such processing using the layer frequency, message processing for weakly disturbed events can be performed.

[0092] Fig. 7 is a flowchart for describing the processing in which the management system 106 calculates an average lifetime of each type of consumable. This processing is implemented by executing a program by the CPU 251 of the server computer as a component of the management system 106.

[0093] In step S701, the consumable life management unit 363 obtains replacement history information regarding the consumables based on a message including event information regarding the replacement of a consumable received from the storage 254 or the unillustrated storage service in the network via the monitoring device. If a message containing the event information regarding the replacement of a consumable is received multiple times from the same transmission source, the consumable life management unit 363 analyzes the contents of the messages. If the serial numbers are different from each other, the consumable life management unit 363 determines that the consumable has been replaced.Based on this determination, the device information management unit 359 records the up-shift frequency included in the message from which the replacement was determined as the value of the total counter at the time of replacement of the consumable.

[0094] In step S702, the consumable life management unit 363 calculates an average life of each type of consumable or consumable material by using the replacement history information related to the consumables. The type of consumable can be identified from the consumable or consumable material identifier. The calculation processing for the average life is performed according to the following equation: "Average lifetime" = Σ ((Total count at current replacement of consumable) - (Total count at previous replacement of consumable)) / Frequency of replacement. In step S703, the device information management unit 359 executes notification processing regarding the average lifetime calculated by the consumable lifetime management unit 363. In the notification processing, the average lifetime of each type of consumable identified by the consumable ID is provided from the www server program via the network. The service personnel or a responsible person from the manufacturer's factory of the modeling device 102 can obtain the average lifetimes of the consumables during current operation using a web browser.

[0095] Based on the processing result after Fig. 7 an analysis can be carried out to enable systematic production and supply planning for the consumables in the future.

[0096] Fig. 8 is a flowchart illustrating the processing in which the monitoring device sends information about processing details of the 3D object shape processing when the modeling device 102 completes a single round of 3D object shape processing based on model data. This processing is implemented by executing a program for implementing the monitoring device by the CPU in the modeling device 102 or the information processing device on which the monitoring device is running. Multiple 3D objects can be generated from a single round of shape processing.

[0097] In step S801, the device information management unit 305 detects a start of 3D object shape processing according to a notification from the modeling management unit 303. The device information management unit 305 records the time (year, month, date, and day) when the shape processing is started, as well as the layering frequency stored in the memory 204 as layer count information at the time of the start.

[0098] In step S802, the device information management unit 305 determines the completion of the modeling processing according to a notification from the modeling management unit 303. The device information management unit 305 records the time (year, month, date, and day) at which the modeling processing is completed and the number of times of piling stored in the memory 204 as the layer count information value at the time of completion.

[0099] In step S803, the device information management unit 305 obtains the amounts of consumables (modeling material and support material) supplied by the consumable replenishment unit 212 during the 3D object molding processing, recorded in the memory 204. The generation unit 309 generates a message containing information indicating the obtained supply amounts of consumables. The generated message further includes a file name of the model data subjected to the 3D object molding processing, an owner name of the model data, the time (year, month, date, and time) when the modeling processing was started, the stacking frequency indicating the total count at the start time, the time (year, month, date, and time) when the modeling processing was completed, and the stacking frequency indicating the total count at the completion time.

[0100] In step S804, the communication control unit 308 executes control to send the generated message to the management system 106 via the network. The management system 106 uses the message for the purpose of reporting the consumption amounts of consumables for each round of 3D object shape processing and for the purpose of invoicing. (Application examples)

[0101] The schedule for regular maintenance work of the modeling device 102 by the service personnel was originally set on a time basis, for example, once a month.

[0102] In an exemplary embodiment of the invention, the replenishment frequency, which serves as a total count from which the operating status of the modeling device 102 since the start of use can be comprehensively determined, is sent by the management system 106 on a regular basis. This allows for flexible response regarding the scheduling of regular maintenance work. For example, if the replenishment frequency after the previous maintenance is greater than expected, service personnel can arrive earlier than usual to perform maintenance work.

[0103] The management system 106 can record the year, month, date, and time when the service personnel perform maintenance work. The device information management unit 305 of the management system 106 automatically calculates a change in the shift frequency value, which serves as the total count, every day based on the shift frequency value regularly sent on the day of the maintenance work and the shift frequency value regularly sent thereafter. If the calculated change amount exceeds a predetermined value, the notification management unit 357 automatically sends a maintenance request email to the service personnel's address. Further embodiments

[0104] One or more embodiments of the invention may also be practiced by a computer, a system, or an apparatus that reads and executes computer-executable instructions (e.g., one or more programs) stored on a storage medium (which may also be more particularly referred to as a "non-transitory, computer-readable storage medium") to perform the functions of one or more of the embodiments described above, and / or whichwhich includes one or more circuits (e.g., an application-specific integrated circuit (ASIC)) to perform the functions of one or more of the embodiments described above, further by a method performed by the computer of the system or device, for example, by reading and executing the computer-executable instructions from the storage medium to perform the functions of one or more embodiments described above, and / or to control the one or more circuits to perform the functions of one or more of the embodiments described above. The computer may include one or more processors (e.g., a central processing unit (CPU), a microprocessing unit (MPU)), and it may include a network of separate computers or separate processors for reading and executing the computer-executable instructions.The computer-executable instructions can be supplied to the computer, for example, from a network or the storage medium. The storage medium can include, for example, one or more of the following media: a hard disk, random access memory (RAM), read-only memory (ROM), distributed computing system memory, an optical disk (e.g., a compact disk (CD), a digital versatile disk (DVD), or a Blu-ray disc (BD). ® ), a flash memory, a memory card, and the like.

[0105] While the present invention has been described with reference to exemplary embodiments, it should be understood that the invention is not limited to the disclosed embodiments. The scope of the present claims is to be accorded the broadest possible interpretation to encompass all modifications and equivalent structures and functions.

Claims

[1] System comprising: a monitoring device configured to monitor a modeling device (102) configured to form a three-dimensional object (405, 414); and a management system (106) configured to communicate with the monitoring device via a network (108); wherein the monitoring device contains: a detection device (306) for detecting a number of layers recorded in a storage unit (204) of the modeling device, a generating device (307) for generating a message containing identification information for identifying the modeling device and the detected number of layers, and a transmission device (301) for transmitting the message generated by the generation device to the management system, and where the management system includes: a receiving device (351) for receiving the message from the monitoring device, and a storage device (359) for storing the identification information and number of layers contained in the received message in a memory (254), characterized by , that the number of layers detected by the detecting means indicates a total number of layers in the mold processing of the plurality of three-dimensional objects corresponding to a plurality of orders by a molding means (209) of the modeling apparatus. [2] The system according to claim 1, wherein the transmission device is configured to transmit the message containing the identification information for identifying the modeling device and the detected number of layers regularly according to a schedule specified by the management system. [3] The system according to claim 1 or 2, wherein the generating means is configured to, when an event has occurred in the modeling device, generate a message (S552) containing information representing the occurred event, information indicating a time at which the event occurred, the identification information for identifying the modeling device, and the number of layers obtained at the time of occurrence of the event, and wherein the transmitting means is configured to transmit the generated message to the management system (S553) corresponding to the occurrence of the event in the modeling device. [4] A system according to any one of claims 1 to 3, wherein the monitoring device is incorporated into the modeling device. [5] A method performed by a monitoring device configured to monitor a modeling device (102) configured to form a three-dimensional object (405, 414) and by a management system (106) configured to communicate with the monitoring device via a network (108), comprising the following steps: a detecting step (S502, S552) for detecting - by the monitoring device - a number of layers recorded in a storage unit (204) of the modeling device; a generating step (S502, S552) of generating, by the monitoring device, a message containing identification information for identifying the modeling device and the detected number of layers; a transmission step (S503, S553) of transmitting the generated message by the monitoring device to the management system; a receiving step (S601) of receiving the message from the monitoring device by the management system; and a storage step (S604) of storing the identification information and number of layers contained in the received message in a memory (254) by the management system, characterized by , that . the number of layers detected in the detecting step indicates a total number of layers in the mold processing of the plurality of three-dimensional objects corresponding to a plurality of orders by a molding device (209) of the modeling apparatus. [6] A monitoring device for monitoring a modeling device (102) configured to form a three-dimensional object (405, 414), comprising: a detection device (306) for detecting a number of layers recorded in a storage unit (204) of the modeling device; a generating device (307) for generating a message containing identification information for identifying the modeling device and the detected number of layers; and a transmission device (301) for transmitting the message generated by the generation device to a management system, characterized by that the number of layers detected by the detecting means indicates a total number of layers in the mold processing of the plurality of three-dimensional objects corresponding to a plurality of orders by a molding means (209) of the modeling apparatus. [7] The monitoring device according to claim 6, wherein the transmission device is configured to transmit the message containing the identification information for identifying the modeling device and the detected number of layers regularly according to a schedule specified by the management system (S503). [8] The monitoring device according to claim 6 or 7, wherein the generating means is configured to, when an event has occurred in the modeling device, generate (S552) a message containing information representing the occurred event, information indicating a time at which the event occurred, the identification information for identifying the modeling device, and the number of layers obtained at the time of occurrence of the event, and wherein the transmission device is configured to transmit the generated message to the management system according to the occurrence of the event in the modeling device (S553). [9] The monitoring device according to any one of claims 6 to 8, wherein the generating means is configured to generate (S803), when the mold processing is executed in the modeling device, a message describing processing details, including information about a time at which the mold processing is started, information about a time at which the mold processing is completed, the number of layers recorded in the storage unit of the modeling device, and a consumption amount of a consumable used in the mold processing, and wherein the transmitting means is configured to transmit (S804) the generated message describing the processing details to the management system after the mold processing is completed. [10] The monitoring device according to any one of claims 6 to 9, wherein, when a modeling method of the modeling device is material layer lamination, the number of layers recorded in the storage unit of the modeling device indicates a number of material layers (402) laminated during the molding processing. [11] The monitoring device according to any one of claims 6 to 10, wherein, when a modeling method of the modeling device is a stereolithography method, the number of layers recorded in the storage unit of the modeling device indicates a number of times a layer of a consumable material has been stacked on a stage of the molding device during molding processing. [12] The monitoring device according to any one of claims 6 to 11, wherein, when a modeling method of the modeling device is an inkjet method, the number of layers recorded in the storage unit of the modeling device indicates a number of times a stage (417) of the molding device was moved layer by layer in a direction perpendicular to a horizontal surface of the stage during molding processing. [13] Monitoring device according to one of claims 6 to 12, wherein the monitoring device is incorporated in the modeling device. [14] The monitoring device according to claim 6, wherein the transmission device is further configured to transmit a number of layers of mold processing performed according to an order by the molding device of the modeling device to the management system. [15] A method for a monitoring device that monitors a modeling device (102) configured to form a three-dimensional object (404, 414), comprising the steps of: a detecting step (S502, S552) of detecting a number of layers recorded in a storage unit (204) of the modeling device; a generating step (S502, S552) of generating a message containing identification information for identifying the modeling device and the detected number of layers; and a transmission step (S503, S553) of transmitting the generated message to a management system, characterized by that the number of layers detected in the detecting step indicates a total number of layers in the mold processing of the plurality of three-dimensional objects corresponding to a plurality of orders by a molding device (209) of the modeling apparatus. [16] The method of claim 15, wherein the monitoring device is incorporated into the modeling device. [17] A computer-readable storage medium having stored thereon a computer program for causing a computer to carry out the method of claim 15.

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