Multifunctional technological effector of robot for hybrid additive manufacturing

Abstract

Multifunctional technological effector of robot for hybrid additive manufacturing is designed in such a way that a holder (2) of the technological device for additive manufacturing is attached to a adapter (1), so that it allows continuous adjustment of its position in two axes by means of mutually perpendicular grooves on the adapter (1) and grooves on the holder (2). On the holder (2) of the technological device for additive manufacturing, a technological device (3) for additive manufacturing is attached so that its position in the third axis can be adjusted by means of the grooves in the holder (2). The technological device (3) of additive manufacturing is equipped with an end tool (4) of additive manufacturing, which performs the application of the building material. On the adapter (1) is attached a technological device (6) for subtractive production equipped with an end tool (7) of subtractive production, which performs the removal of material. The attachment to the adapter (1) is implemented by means of the holder (5), which allows adjustment of the end position of the tool (7) in one axis. A 3D scanner (9) is attached to the adapter (1) by means of a holder (8) of the 3D scanner. The adapter (1) equipped with additive manufacturing technology, subtractive manufacturing technology and 3D scanning technology forms the multifunctional effector for hybrid additive manufacturing. The adapter (1) so equipped is attached to a robotic arm (10). The three-axis adjustment elements of the technological devices enable the adjustment of the tool positions of the end points of additive and subtractive manufacturing so that they lie on the common circle centred on the axis of rotation of the adapter on the robotic arm, and thus enable the end point of the active tool to be changed precisely when rotated by 180°.

Description

[0001] Multifunctional technological effector of robot for hybrid additive manufacturing

[0002] Technical field

[0003] The invention relates to the construction of multifunctional technological effector of robot for hybrid additive manufacturing. The invention falls within the fields of hybrid additive manufacturing, manufacturing technology, robotics and mechanical engineering.

[0004] Background

[0005] Additive manufacturing processes are currently coming to the fore, their application and advantages partially replace subtractive manufacturing processes. As example, we can mention the technology of hard surfacing or 3D printing. However, the kinematic structure of conventional 3D printers significantly limits the printing process of shape-structured components. The solution to this problem lies in the use of industrial robots with fitted print head, the kinematics of which opens a whole new perspective in the field of 3D printing. Once the component has been created using the additive process, the robotic arm can also be used for machining functional surfaces using finishing subtractive operations such as drilling holes, milling functional surfaces, and so on, which fulfils the essence of hybrid additive manufacturing.

[0006] With additive manufacturing, structural parts of all sizes, shapes and structures can be produced quickly, accurately and cost-effectively, especially prototypes or small series.

[0007] Stable, lightweight and especially large - these are the main characteristics of structural parts for aircraft, cars, ships or buildings. It is for such oversized formats that industrial 3D printing is proving to be the ideal manufacturing method. In combination with robotic units and thanks to their enormous reach, even structural parts several metres in size and at the same time very geometrically complex can be produced cost-effectively, simply and from a single piece.

[0008] Printing in the smallest possible layers achieves the highest accuracy and surface quality, but has its limitations. The hardware itself has limits in the minimum layer thickness that it can produce. At the same time, computation time increases in software that has to divide the model into many layers. It also significantly increases the actual printing time, because it takes longer to create one thinner layer, and simultaneously a larger number of layers must be created to produce the entire component.

[0009] Currently, additive manufacturing and subtractive manufacturing technologies are mostly used in manufacturing separately by means of separate manufacturing machines and processes. The component is usually produced as a whole, either by additive manufacturing or by subtractive manufacturing. There are only a few technologies where additive manufacturing is used and then subtractive manufacturing is used for completion.

[0010] The manufacturing process of the component using additive manufacturing technology exclusively allows the combination of different construction materials in a single component, enabling high precision and surface quality to be achieved, but at the price of long manufacturing times. Subtractive manufacturing technologies, on the other hand, face geometric and technological constraints, the impossibility of combining materials in a single component, the impossibility of controlling the internal structure. The sequential use of additive manufacturing of a component and then subtractive manufacturing results in long manufacturing times, long secondary times, the need to produce the whole component first by additive manufacturing technology and only then to finish it by subtractive manufacturing technology. This limits the flexibility of the manufacturing process.

[0011] The utilization of advantages of additive and subtractive manufacturing and the elimination of their shortcomings has led to the integration of additive manufacturing and subtractive manufacturing means into the single design of the multifunctional effector for hybrid additive manufacturing, as the manufacturing tool designed for the robotic kinematic structure according to this invention.

[0012] Summary of the invention

[0013] The above-mentioned shortcomings in the state of the art in the field of robotic manufacturing are eliminated by multifunctional technological effector of robot for hybrid additive manufacturing according to the invention on the basis of the defined requirements. The requirement for compatibility with the robot has been taken into account. The developed effector for hybrid additive manufacturing was designed to be compatible with the industrial robot that would control its movement. Safe and reliable communication must be ensured between the designed effector and robot to avoid collisions between them. The requirement for mechanical stability was taken into account so that the effector was designed to be mechanically stable and have sufficient strength to handle and work with integrated devices, such as the print head and milling spindle, in different directions. Consideration has been given to the requirement for correct positioning and orientation so that the effector is accurately and reliably attached to the connecting flange of the robotic arm. Also, it should allow movement in different directions and thus be able to adapt to the geometry of the object. When pushing or milling, the end of the tool performing the operation must be at the lowest point and the other tool cannot complicate the ongoing process. The requirement for easy replacement and maintenance has been taken into account so that the effector is easily accessible for maintenance and repair. It must also meet the requirement for easy replacement, either of individual components or of the entire effector, eventually its adaptation to other processes. The weight requirement has been taken into account so that, for example, for the robot with load capacity of 4 kg, the total weight of the complete effector does not exceed this value, also taking into account the cutting forces induced during the milling process. The requirement for adequate cooling of the spindle has been taken into account so that the effector is designed in such a way that the milling spindle is sufficiently cooled and cannot be overheated. The requirement for a trouble-free inlet of filament and electrical line has been taken into account so that the filament enters the print head directly and does not crank, which must also be adapted to the effector construction. Consideration must also be given to the power supply for both print head and milling spindle. Then, the essence of the invention is that the multifunctional technological effector for hybrid additive manufacturing comprises the adapter with the flange, wherein the holder of the technological device of subtractive manufacturing with the technological device of subtractive manufacturing with the tool of subtractive manufacturing is attached to the adapter from one side. The spindle of the technological device of subtractive manufacturing is adjustably mounted in the holder of the technological device of subtractive manufacturing in the direction of its axis for continuous adjustment of the position of the end point of the tool of subtractive manufacturing. The technological device of additive manufacturing with the tool of additive manufacturing is attached to the adapter from the other side via the holder of the technological device of additive manufacturing. The adapter and the holder of the technological device of additive manufacturing have the grooves for continuous adjustment of the position of the end point of the additive manufacturing tool in space. The axis of the tool of additive manufacturing of the technological device of additive manufacturing and the axis of the tool of subtractive manufacturing of the technological device of subtractive manufacturing are parallel. The end point of the tool of additive manufacturing of the technological device of additive manufacturing and the end point of the tool of subtractive manufacturing of the technological device of subtractive manufacturing lie on the circle centred on the axis of the flange of the adapter and have the angle of 180° or other angle between them, depending on the technological devices used. The 3D scanner is attached via the 3D scanner holder in the axis of the adapter flange on the front side of the adapter.

[0014] Multifunctional technological effector of robot for hybrid additive manufacturing is applicable in technology that consists of the following coupled steps, which can be repeated in any number in the manufacturing process of the component: The additive manufacturing creates the component or part based on the digital 3D CAD model. The 3D scanner creates a digital model of the manufactured component or part with realistic geometry. This digital model serves as the input for the CAM system for controlling the subtractive manufacturing. The subtractive manufacturing produces the functional surfaces and elements of the component.

[0015] According to the invention, the advantages of the construction of multifunctional technological effector of robot for hybrid additive manufacturing are evident from the effects which it externally manifests. In particular, the effects of this invention are that the invention solves the process of manufacturing technology and the construction of the multifunctional effector for hybrid additive manufacturing located on the robotic arm. The proposed manufacturing technology is based on combining additive manufacturing and subtractive manufacturing technology, arbitrarily during the manufacturing process. With this manufacturing technology it is possible to apply the advantages of additive manufacturing, in particular the geometric complexity of the manufactured components, the combination of construction materials used for the manufacturing of the single component, the controlled density and geometry of the internal structure, etc., all through the roughing process in order to minimize the manufacturing times. The proposed technology of manufacturing applies the advantages of subtractive manufacturing, in particular the geometric accuracy and surface quality of the functional surfaces and elements of the manufactured component. The component is firstly built by roughing additive manufacturing based on the 3D CAD model. Its manufactured elements represent the workpiece for subtractive manufacturing, which modifies the functional surfaces. Since the real manufactured component or its part by additive manufacturing (especially in roughing) differs from the original 3D CAD model, the proposed technology is complemented by 3D surface scanning as the necessary step between the application of additive and subtractive manufacturing in order to achieve the highest possible manufacturing precision.

[0016] Overview of figures on the drawings

[0017] Multifunctional technological effector of robot for hybrid additive manufacturing according to the invention will be further explained in the drawings, wherein:

[0018] Fig. 1, in axonometric view, shows the view of the complete effector assembly.

[0019] Fig. 2, in one axonometric view, shows the view of location of the end points of the tools of additive and subtractive manufacturing of the technological devices lying on the circle.

[0020] Fig. 3, in the second axonometric view, shows the view of location of the end points of the tools of additive and subtractive manufacturing of the technological device lying on the circle.

[0021] Fig. 4, in axonometric view, shows the view of effector attached to the robotic arm of robot. Fig. 5, in axonometric view, shows the view of effector attached to the robotic arm of robot with the print head in working position.

[0022] Fig. 6, in axonometric view, shows the view of effector attached to the robotic arm of robot with the milling spindle in working position.

[0023] Examples of embodiment of the invention

[0024] It is understood that the various embodiments of multifunctional technological effector of robot for hybrid additive manufacturing of the invention are presented for illustrative purposes and not as limitations of the solutions.

[0025] In this example of the specific embodiment, the construction of multifunctional technological effector of robot e.g. ABB IRB 1100-4 / 0.58 for hybrid additive manufacturing according to the invention is described, as illustrated in Figs. 1-3. It comprises the adapter 1 with flange of the adapter 1, wherein the holder 5 of the technological device of subtractive manufacturing with the technological device 6 of subtractive manufacturing with the tool 7 of subtractive manufacturing is attached to the adapter 1 from one side. The spindle of the technological device 6 of subtractive manufacturing is adjustably mounted in the direction of its axis in the holder 5 of the technological device of subtractive manufacturing for continuous adjustment of the position of the end point of the tool 7 of subtractive manufacturing. On the adapter 1, the technological device 3 of additive manufacturing is attached to the tool 4 of additive manufacturing from the other side via the holder 2 of the technological device of additive manufacturing. The adapter 1 and the holder 2 of the technological device of additive manufacturing have grooves for continuous adjustment of the position of the end point of the tool 4 of additive manufacturing in space.

[0026] The axis of the tool 4 of additive manufacturing - nozzle of the technological device 3 of additive manufacturing and the axis of the tool 7 of subtractive manufacturing of the technological device 6 of subtractive manufacturing are parallel. The end point of the tool 4 of additive manufacturing - nozzle of the technological device 3 of additive manufacturing and the end point of the tool 7 of subtractive manufacturing of the technological device 6 of subtractive manufacturing lie on the circle centred on the axis of the flange of the adapter 1 and have the angle of 180° between them. The 3D scanner 9 is attached in the axis of the flange of the adapter 1 on the front side of the adapter 1 via the holder 8 of the 3D scanner.

[0027] The adapter 1 for tool attachment is attached to the flange of the robotic arm 10 of robot by means of four screws with cylindrical head and internal hexagon M5xl5, as shown in Fig. 4. The milling spindle 6 is inserted into the holder 5 and the spindle holder 5 itself is attached to the adapter 1 by means of four screws M6xl00 and associated washers and nuts. Two M5 low T-nuts are inserted into each of the T-slots, which are on the top of the adapter 1, so that the modified steel angle can subsequently be mounted. This angle, which serves as the holder 2 of the print head 3, is attached with flat washers and cylindrical head screws and internal hexagon M5x8 to the aforementioned T-nuts. The print head 3 will be directly anchored to the modified angle by flat washers, three cylindrical head screws and internal hexagon, one of dimension M3x8 and two of dimension M3x30.

[0028] The flange of the adapter 1 is designed exactly according to the robot's connecting flange, so that they are compatible with each other and there are no problems when connecting adapter 1. When changing from the pushing process to the milling process, it is sufficient to rotate the sixth axis of the robot by 180°, which is shown in Figs. 5 and 6. By this repositioning of robot, the working positions are exchanged and the end of the milling cutter 7 reaches exactly the same point where the additive manufacturing tool 4, the nozzle, was previously located, which will greatly facilitate the work of programming the robot's trajectory.

[0029] The adapter 1 is attached to the holder 5, in which the spindle 6 is inserted and firmly fixed. By integrating of this original holder 5, satisfactory cooling of the milling spindle 6 is ensured. The print head 3 is mounted on the steel angle and the axis of the tool 4 of additive manufacturing - nozzle, is parallel to axis of the spindle 6.

[0030] Replacement and maintenance is very easy in this case, as all components are easily accessible and easily replaceable. The weight should not exceed the specified limit. The filament inlet to the print head 3 and the electrical supply to both tools are without significant complications, and its guiding can be easily solved by attaching it, for example, to the steel angle and can continue along the robot arm.

[0031] Industrial applicability

[0032] Multifunctional technological effector of robot for hybrid additive manufacturing according to the invention is applicable in mechanical manufacturing, mechanical engineering industry, aerospace industry, automotive industry and similar fields.

Claims

CLAIMS1. A multifunctional technological effector of a robot for hybrid additive manufacturing, characterized in that it comprises an adapter (1) with a flange, wherein a holder (5) of a technological device of subtractive manufacturing with a technological device (6) of subtractive manufacturing with a tool (7) of subtractive manufacturing is attached to the adapter (1) from one side; the technological device (3) of additive manufacturing with a tool (4) of additive manufacturing is attached to the adapter (1) from the other side via the holder (2) of the technological device of additive manufacturing; an axis of the tool (4) of additive manufacturing of the technological device (3) of additive manufacturing and the axis of the tool (7) of subtractive manufacturing of the technological device (6) of subtractive manufacturing are parallel to each other, wherein the end point of the tool (4) of additive manufacturing of the technological device (3) of additive manufacturing and the end point of the tool (7) of subtractive manufacturing of the technological device (6) of subtractive manufacturing lie on the circle centred on the axis of the flange of the adapter (1); a 3D scanner (9) is attached in the axis of the adapter flange (1) on the front side of the adapter (1) via a holder (8) of the 3D scanner.

2. The multifunctional technological effector of robot for hybrid additive manufacturing according to claim 1, characterized in that the end point of the tool (4) of additive manufacturing of the technological device (3) of additive manufacturing and the end point of the tool (7) of subtractive manufacturing of the technological device (6) of subtractive manufacturing have the angle of 180° between them.

3. The multifunctional technological effector of robot for hybrid additive manufacturing according to any one of claims 1 to 2, characterized in that the adapter (1) and the holder (2) of the technological device (3) of additive manufacturing have grooves for continuous adjustment of the position of the end point of the tool (4) of additive manufacturing in space.

4. Multifunctional technological effector of robot for hybrid additive manufacturing according to any one of claims 1 to 3, characterized in that a spindle of the technological device (6) of subtractive manufacturing is adjustably mounted in the direction of its axis in the holder (5) of the technological device of subtractive manufacturing for continuous adjustment of the position of the end point of the tool (7) of subtractive manufacturing.

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