Modular machine for manufacturing by addition, subtraction or transformation of material

Abstract

A modular machine (1) for manufacturing objects is described, comprising: a frame (20), a support plate (24), at least one manufacturing module (10) comprising a docking station (11) and a manufacturing head (12) removable relative to the docking station, a device (30) for moving a manufacturing head relative to the support plate, and a main controller (41), configured to control the moving device, each manufacturing module docking station comprising a secondary controller (110), the frame comprising a plurality of locations (25) for manufacturing modules, and each docking station and each location are configured to allow the mounting of a docking station in a removable manner in a location of the frame by establishing communication between the secondary controller and the main controller when the docking station is mounted in a location of the frame. Abstract Figure: Figure 1

Description

Title of the invention: Modular machine for manufacturing by addition, subtraction or transformation of material Technical field

[0001] The present disclosure relates to a modular manufacturing machine by addition, subtraction or transformation of material, which may in particular comprise one or more three-dimensional printing modules by molten wire deposition. Prior art

[0002] It is known to manufacture objects by 3D printing (or additive manufacturing), in particular by fused deposition modeling technology, also called FDM (English acronym for "Fused Deposition Modeling"). A 3D printing machine by fused deposition modeling conventionally comprises a frame comprising a location for a spool of filament to be deposited, a support plate for an object to be manufactured, and a heating nozzle movable relative to the support plate, into which filament unwound from the spool is fed. The heating nozzle makes it possible to deposit the molten filament in successive layers to form the object to be manufactured. A controller makes it possible to control the movement of the nozzle, also the heating, the filament drive means, etc.

[0003] A disadvantage linked to this type of machine is that it generally comprises one or two reels and associated nozzles, which limits the diversity of possible parts, since it may be necessary to change the reel during manufacture to be able to print parts of different colors, or even to change a nozzle associated with a reel to be able to print according to a desired printing width, because this printing width is determined by the nozzle which generally has a section of constant diameter.

[0004] Furthermore, in order to be able to manufacture complex objects, involving additional tasks of inserting components, engraving, etc., it is necessary to have another machine to carry out these additional steps. Summary

[0005] The present disclosure improves the situation.

[0006] In particular, an aim of the present disclosure is to propose a modular machine for manufacturing objects, offering a diversity of tools for simpler and faster manufacturing of objects, possibly complex.

[0007] Another object of the present disclosure is to provide a machine which may include one or more fused deposition printing modules.

[0008] Another object of the present disclosure is to provide a machine whose confi- The configuration of the modules can be changed easily.

[0009] A modular machine is proposed for the manufacture of objects by addition, subtraction or transformation of material, comprising: - a frame, - a support plate for an object to be manufactured, - at least one manufacturing module, each manufacturing module comprising a docking station and a manufacturing head removable from the docking station, - a device for moving a manufacturing head relative to the support plate, and - a main controller, configured to control the movement device, characterized in that each manufacturing module docking station comprises a secondary controller, the rack comprises a plurality of slots for manufacturing modules, and in that each module docking station and each slot comprises mechanical and electrical connectors adapted to allow a docking station to be removably mounted in any of the slots of the rack, and to establish communication between the secondary controller of the docking station and the primary controller when the docking station is mounted in a slot of the rack.

[0010] In embodiments, each docking station of a manufacturing module comprises a memory storing configuration information of the manufacturing module, and the secondary controller is configured to transmit said configuration information to the primary controller during an initialization phase of the manufacturing module.

[0011] In embodiments, each docking station includes a removable build head presence sensor, and the secondary controller is configured to communicate a presence or absence status of the removable build head to the primary controller.

[0012] In embodiments, the moving device comprises a carriage movable in a plane parallel to the support plate, the carriage comprising mechanical and electrical connection means with a manufacturing head, a motor, and a dog clutch driven by the motor.

[0013] In embodiments, the machine comprises two alignments of locations of the manufacturing modules, arranged parallel to each other, on either side of the support plate of the object to be manufactured.

[0014] In embodiments, the device for moving a manufacturing head comprises an arm movable in translation in a direction parallel to the alignments locations of the modules, and a carriage movable in translation in the arm, in a direction perpendicular to the direction of movement of the arm, the carriage comprising removable gripping means for a manufacturing head of a module, arranged on either side of the carriage in its direction of movement.

[0015] In embodiments, the device for moving a manufacturing head comprises a carriage movable in a plane parallel to the support plate, and at least one belt for moving the movable carriage defining a closed contour, and the locations for the manufacturing modules are located inside the contour defined by the belt.

[0016] In embodiments, the moving device comprises two superimposed moving belts moving in opposite directions.

[0017] In embodiments, the machine comprises a module slot support part comprising the mechanical and electrical connectors of a plurality of module slots, an electronic board on which the electrical connectors are mounted, and a housing for the passage of each belt.

[0018] In embodiments, the machine comprises at least one fused deposition modeling printing module, the docking station of which is configured to supply filament to the head, and the head comprises a wire heater, and a deposition nozzle.

[0019] In embodiments, the head of the fused deposition modeling printing module further comprises a drive mechanism capable of being driven by the carriage motor via a dog clutch, when the carriage is connected to the head.

[0020] In embodiments, the frame includes a spool holder and a wire collection bin disposed beneath each manufacturing module location.

[0021] In embodiments, the secondary controller of the docking station of the fused filament deposition printing module is configured to transmit to the main controller information relating to a length of filament consumed and / or an alert relating to an event such as a break or absence of filament.

[0022] In embodiments, the main controller is configured to control the implementation of a manufacturing sequence involving the operation, successively, of a first manufacturing module and the fused deposition modeling module, and the docking station of the fused deposition modeling module is further configured, upon receipt of instructions from the main controller, to preheat and preload the print head with filament, during the operation of the first manufacturing module.

[0023] In embodiments, the machine further comprises at least one manufacturing module from the following group: - Writing module, Milling module Liquid deposition module, Cutting module, Laser module, Gripping and depositing module, Material injection module, Dimensional measurement module, Engraving module, Smoothing module, Continuous fiber deposition module, Resin deposition and polymerization module.

[0024] According to another object, there is described a manufacturing or control module adapted to be used in a machine according to the preceding description, the manufacturing module comprising a docking station and a manufacturing head removable with respect to the docking station, in which the docking station comprises a controller, and comprises connection means, for example electrical and mechanical connectors, adapted to allow its mounting on the frame of the machine in a removable manner.

[0025] In embodiments the docking station and the manufacturing head comprise controlled electromagnetic coupling means, and electrical connection means.

[0026] In embodiments, the docking station comprises a motor and a coupling member with an output shaft of the motor, and the manufacturing head comprises moving mechanical parts and a coupling member adapted to cooperate with the coupling member of the docking station and to drive the moving mechanical parts into motion once the coupling has been achieved.

[0027] In embodiments, the module is a fused deposition modeling printing module, wherein the docking station is configured to supply filament to the head, and the head includes a filament heater and a deposition nozzle.

[0028] In embodiments, the docking station further comprises at least one sensor adapted to detect a break or absence of filament, and / or to measure a length of filament consumed.

[0029] The proposed machine comprises one or more manufacturing modules, each module comprising a docking station removably mounted on a location dedicated for this purpose on the machine frame. The location and the docking station being provided with electrical connectors, and the docking station comprising its own controller, the mounting of a module on the frame makes it possible to put the controller of the docking station in communication with the main controller of the machine. Thanks to this communication, the main controller can know the configuration of the machine (number of modules, function of each module, settings associated with each module) and manage the operation of the machine accordingly.

[0030] Each docking station may also include a presence sensor for the associated tool head, and communicate the present or absent state of the tool head to the main controller. Each docking station may also include additional functionalities that may depend on the nature of the manufacturing tool formed by the module. Thus, a docking station of a fused deposition modeling printing module may also include functionalities for priming and controlling the presence of filament, and for measuring the quantity of filament used.

[0031] The mechanical configuration of the machine is also adapted to its modular nature. Thus, in embodiments, the locations for the modules are aligned according to two alignments arranged on either side of the support plate. The device for moving a module head comprises a carriage movable between the alignments, and which symmetrically comprises means for removable connection to a module head to be able to connect with heads of each of the alignments. The movement of the carriage is carried out by at least one belt delimiting a closed circuit, inside which the locations of the modules are located, so that the movement of the manufacturing heads is not hindered by the circulation of the belts. Brief description of the drawings

[0032] Other characteristics, details and advantages will appear on reading the detailed description below, and on analyzing the attached drawings, in which: Fig.l

[0033] [Fig.l] schematically represents an example of a modular machine according to one embodiment. Fig. 2

[0034] [Fig.2] schematically shows an example of an arrangement of a device for placement of a manufacturing head and manufacturing module locations according to one embodiment. Fig. 3

[0035] [Fig.3] shows an example of a support part carrying a plurality of fa modules brication. Fig. 4

[0036] [Fig.4] represents a top view, in section, of an example of a support part of module locations. Fig. 5

[0037] [Fig.5] represents an example of a movable arm of a device for moving a manufacturing head. Fig. 6

[0038] [Fig.6] represents an example of an end piece of a movable arm. Fig. 7

[0039] [Fig.7] schematically represents, in top view, means of coupling and alignment between a docking station of a manufacturing module, a manufacturing head and a mobile carriage of a device for moving the manufacturing head according to one embodiment. Fig. 8

[0040] [Fig.8] schematically represents, in top view, an example of a mobile carriage of a moving device according to one embodiment. Fig. 9

[0041] [Fig.9] represents an exploded view, without cover, of a docking station of a fused deposition printing module according to one embodiment. Fig. 10

[0042] [Fig. 10] schematically represents the arrangement of a fused wire deposition manufacturing module according to one embodiment. Fig. 11

[0043] [Fig. 11] represents a view of a modular manufacturing machine according to one embodiment.

[0044] Detailed description of at least one embodiment

[0045] With reference to figures 1, 2 and 11, embodiments will now be described of a modular machine 1 for the manufacture of objects by addition, subtraction or transformation of material.

[0046] The machine may comprise a plurality of different manufacturing modules 10, for carrying out different types of operation on an object to be manufactured, the manufacturing modules being able to be used at different times to carry out successive steps in the manufacture of the same object. In particular, and as described in more detail below, the machine may comprise one or more fused filament deposition printing modules. In the case where it comprises several, the different modules may correspond to different colors and / or materials and / or diameters of deposited filament.

[0047] Alternatively or in addition, the machine 1 may comprise one or more manufacturing modules 10 of different types. For example, the machine may comprise one or more of the modules listed below: writing module, milling module, - liquid deposition module, - cutting module, - laser module, - gripping and depositing module, for example to position an insert in a part being manufactured, - dimensional measurement module, for example two-dimensional or three-dimensional measurement, - engraving module, including for example a diamond engraving tip, - Smoothing module, for example for smoothing plastic surfaces, - Continuous fiber deposition module, for example adapted to produce a composite deposition of molten wire around a continuous unmolten wire, - Resin deposition and polymerization module.

[0048] It is understood from the above list that the term “manufacturing module” also includes modules involved during the manufacture of a part to carry out control operations on the part, without necessarily carrying out a manufacturing operation by addition, subtraction or transformation of material on this part.

[0049] With reference to Figures 1 and 11, the machine 1 comprises a frame 20, the frame being able for example to comprise a parallelepipedal enclosure 21 delimited at least by peripheral walls 22 and an upper wall 23, making it possible to protect the contents of the enclosure, that is to say the components of the machine and the part being manufactured, from external contamination and also making it possible to ensure the safety of the operators. At least one of the peripheral walls may comprise at least one opening 220 allowing access to the interior of the enclosure 21 by an operator for maintenance, cleaning, changing modules, if necessary filament spools for fused deposition printing, removal of filament scraps and handling and / or removal of the part to be manufactured, etc.

[0050] The machine 1 also comprises a support plate 24 for a part to be manufactured, this plate being able to be rectangular in shape and being advantageously movable in translation on a z axis perpendicular to the plane of the plate. In this case, the support plate 24 is mounted in translation on a rigid plate (not shown). In embodiments, the support plate 24 can be heated. If necessary, it can comprise two metal plates, for example made of aluminum, between which is positioned a heating element, for example a resistor. On these two metal plates is fixed an additional plate forming the working surface on which the part is placed. The support plate 24 can also comprise, at the periphery of the working surface, one or more rules comprising patterns or indentations making it possible to form marks for calibration, control and / or manufacturing operations.The plate forming the working surface of the table top. support 24 can be made of glass or metal, for example steel, possibly covered with a thermoplastic polymer such as polyetherimide (PEI) in the case of fused deposition printing, to ensure good heat resistance.

[0051] As described in more detail below, and as visible for example in [Fig. 3], each manufacturing module 10 comprises a docking station 11, which is mounted on a location of the frame provided for this purpose, and a manufacturing head 12 which is removable relative to the docking station. The modular machine 1 further comprises a device 30 for moving a manufacturing head 12 of a manufacturing module 10 relative to the support plate. As detailed below, the moving device 30 is adapted to retrieve a manufacturing head of a manufacturing module 10 in its docking station 11, to move it relative to the support plate in order to carry out a manufacturing or inspection step of a part, then to replace it in the docking station 11 of the module.

[0052] The machine 1 also comprises a main controller 41, configured to supervise the operation of the machine, in order to produce a part to be manufactured according to a determined sequence of manufacturing steps.

[0053] In embodiments, the machine 1 comprises a computer 40, which may be co-located with the machine 1, or be remote from the machine and connected to it via a communication network such as the internet or an intranet. The computer 40 comprises one or more processors forming the main controller 41, one or more memories 42, including a non-volatile memory storing code instructions executed by the main controller 41 for controlling the operation of the machine 1. In particular, the main controller 41 is configured to retrieve and execute computer files for controlling the manufacturing of a part, for example files in gcode format.

[0054] The computer may also comprise at least one user interface 43 for receiving instructions from an operator and / or for displaying, on a graphical interface, information relating to the operation of the machine (manufacturing step, status of the machine, indication of a fault, etc.). The user interface 43 may thus comprise one or more of a touch screen, a non-touch screen, a mouse, a keyboard, control buttons, etc.

[0055] The user interface 43 thus allows a user to select and execute a manufacturing control computer file, to manually control, outside the manufacturing of a part, the movement device 30 of the machine, to configure certain parameters, etc.

[0056] The machine 1 being modular, it can comprise one or more manufacturing modules 10, according to a configuration which varies over time, that is to say that the number and nature of the manufacturing modules installed in the machine at a given time can be modified as needed, for example according to the specifications of the part to be manufactured.

[0057] In this respect, the frame of the machine comprises a plurality of locations 25 for manufacturing modules, the number and position of the locations being able to be fixed. Advantageously, the frame comprises at least 2 module locations, for example between 2 and 20 locations, for example 10 or 12 locations. The machine 1 therefore makes it possible to use a number of different tools equal to the number of locations for the manufacture of the same part, allowing rapid tool changes during manufacture. In addition, for fused deposition printing modules, having a large number of print heads 12 makes it possible to improve the possibilities and performance of the machine. Indeed, not only is the number of materials or colors available for the same part increased, but the use of print heads with suitable nozzle diameters makes it possible to significantly reduce the manufacturing time.Since 3D printing is a volume printing process, doubling the nozzle diameter allows for an eightfold increase in printing speed. Print head nozzles can have a diameter ranging from 0.25 to 2 mm, for example. Since tool change times are in the order of a few seconds, the speed gains achieved more than compensate for the time spent changing tools.

[0058] Each location 25 comprises mechanical and electrical connectors adapted to cooperate with mechanical 250 and electrical 251 connectors of a docking station of a manufacturing module in a removable manner so as to mount a docking station of a module on a location in a removable manner, by making an electrical connection between the docking station and the frame when it is put in place. The electrical connectors are in turn connected to the main controller 41 of the machine. By "mechanical connector" is meant any connection means allowing the docking station to be mounted in a removable manner on the frame, including, where appropriate, by magnetic means.

[0059] In addition, each docking station 11 comprises a secondary controller 110, for example of the microprocessor or microcontroller type, allowing, when connecting a docking station to a location of the rack, communication to be established between the secondary controller 110 of a docking station and the main controller 41 of the machine.

[0060] Each docking station 11 advantageously comprises a memory (not shown), for example a non-volatile memory of the ROM type, for example of the EEPROM type, storing configuration information of the manufacturing module (module identifier, module type, module parameters, etc.), and for storing code instructions executed by the secondary controller 110.

[0061] Thus, when mounting a manufacturing module 10 on a location of the frame, the secondary controller 110 and the main controller 41 are configured to implement an initialization phase during which the main controller 41 automatically detects the presence of a manufacturing module 10 on a determined location 25, and receives configuration information of the manufacturing module transmitted by the secondary controller 110 of the module. The main controller 41 is also adapted to carry out an automatic calibration based in particular on the configuration information received. Thus, the exact configuration of the machine, namely the number, arrangement and type of each module, is known at all times to the main controller 41.

[0062] Each docking station 11 may also comprise a presence sensor (not shown) of the removable manufacturing head 12, and the secondary controller 110 is then configured to communicate to the main controller 41 a presence or absence status of the manufacturing head 12.

[0063] With reference to Figures 3 and 4, the locations 25 of the frame 20 for the manufacturing modules 10 will be described in more detail. The frame 20 of the machine may comprise one or more alignments of locations 26 arranged side by side, each alignment comprising, for example, between 2 and 10 locations for modules. In an embodiment shown, for example, in [Fig. 2], the machine 1 may comprise two alignments 26 of locations 25 of modules 10, arranged parallel to each other, on either side of the support plate for the object to be manufactured. This makes it possible to use a symmetrical configuration of the machine and the movement device 30, which is detailed later. Alternatively, the machine 1 may comprise an alignment of locations 26 located on a peripheral wall of the machine, and in particular a bottom wall opposite a wall through which an operator can access the enclosure of the machine.

[0064] In embodiments, the locations are made on a support part 260 secured to the frame, which may be a profile or a formed part. This part advantageously comprises the mechanical 250 and electrical 251 connectors of each location, which are therefore arranged regularly along the length of the part, and a housing in which an electronic card 252 is mounted, for example a printed circuit, on which the electrical connectors 251 are mounted, the electronic card 252 further comprising at least one additional connector 253 for establishing a connection with the main controller 4L. The electrical connectors 252 of the locations and the docking stations are configured to ensure communication between the docking station and the main controller and also to provide the electrical power supply to the docking station, and where appropriate to the manufacturing head when it is mounted in the station.The electrical connectors are advanced. Typically pin connectors, without wires, for structural simplification of the machine. These can typically be spring connectors.

[0065] Each location 25 preferably comprises at least two mechanical connectors 250 adapted to cooperate with complementary connectors of a docking station. The mechanical connectors are for example configured to allow a mechanical connection, for example by snap-fastening or guiding in dedicated housings followed by fixing by screws.

[0066] In embodiments, and as shown for example in [Fig.2], the movement device 30 comprises a movable carriage 31 in a plane parallel to the support plate 24. The movement of the movable carriage is controlled along two perpendicular axes denoted X and Y, these two axes being parallel to the plane of the support plate 24.

[0067] With reference to [Fig. 5], to move the carriage 31, the moving device 30 may comprise an arm 32, movable in translation in a direction Y parallel to the alignment or alignments of the modules, the arm 32 extending in a direction X perpendicular to Y, and the carriage 31 being mounted movable in translation in the arm 32 in this direction X.

[0068] In addition, the moving device 30 comprises at least one belt 33 on which the carriage 31 is mounted, and motors 34 adapted to drive the belt in movement. Advantageously, the belt 33 forms a closed contour inside which the locations 25 of the manufacturing modules are located, which allows the mobile carriage 31 to easily access the manufacturing head 12 of a module 10 to come and retrieve and deposit it. The belt also passes through housings provided for this purpose in the moving arm 32 of the carriage. With reference to [Fig. 5], the moving arm 32 of the carriage may comprise two symmetrical longitudinal parts 320 connected to each other by end parts 321. The longitudinal parts 320 are spaced apart by an interval allowing the mobile carriage 31 to be positioned and moved therein, and each part 320 comprises a longitudinal housing 322 for a portion of the belt.In embodiments, the mobile carriage 31 is mounted in a slide on longitudinal rods 323 carried by each longitudinal part.

[0069] With reference to [Fig. 6], the end pieces 321 may carry guide pulleys 324 for the belts, and possibly rollers 325 allowing them to be mounted on rails 35 provided for this purpose, in order to move the arm in the Y direction. The end pieces 321 advantageously have a U shape, comprising two uprights 326 connected respectively to each longitudinal piece, and separated from each other by a gap wide enough to allow the carriage and a head 12 of a manufacturing module to pass through. The end pieces 321 are thus advantageously dimensioned so that the interval between the uprights 326 is greater than the dimension of a manufacturing module head. The uprights 326 are connected by a base 327 which is slidably mounted in a respective rail 35 and may comprise for this purpose the rollers 325.

[0070] As shown schematically in [Fig. 2], in the embodiments in which the machine 1 comprises two alignments 26 of locations 25 of modules, on either side of the support plate 24, and the contour formed by the belt 33 passes around these alignments then into the arm 32, the contour thus formed by the belt 33 has an H-shaped profile.

[0071] In embodiments, and as shown for example in [Fig. 5], the movement device actually comprises two belts 33, 33' superimposed one above the other in the Z direction, these two belts moving in opposite directions. The motorization is advantageously provided by four stepper motors 34 distributed with two motors per belt. This configuration makes it possible to increase the total motor torque available for the movements, and thus to have significant gains in speed and acceleration, to better distribute the forces on the belts and to allow the use of flexible belts with small pitches, and to generally better balance the forces which are exerted on the moving parts, namely the moving arm 32 and the carriage 31.

[0072] In order to calibrate the zero position, along the X axis, of the carriage 31, the latter may be equipped with an end-of-travel sensor. For example, the end-of-travel sensor may be an optical sensor (not shown). On the movable arm 30, a mark may be arranged to obscure this sensor when the carriage is in the positive X zone. The transition between the masked and unmasked state of the sensor makes it possible to identify the zero position on the X axis. The state of the sensor during the zero-setting command indicates the direction of movement to find the zero, an unmasked state indicating a negative X value, therefore a movement aimed at incrementing X, and a masked state a positive position which implies an inverse movement.

[0073] The carriage 31 may further comprise an image sensor 310 such as a camera or a microscope, making it possible to acquire images of a portion of the support plate, for example to calibrate the position of certain manufacturing module heads, as described in more detail below.

[0074] With reference to figures 7 to 9, the coupling means between a docking station 11 and a manufacturing head 12 of a manufacturing module 10 on the one hand, and between a module manufacturing head 12 and the mobile carriage 31 on the other hand, will now be described in more detail.

[0075] Preferably, the mechanical coupling means between on the one hand a docking station 11 and a manufacturing head 12, and on the other hand between the carriage 31 and a head manufacturing head 12, are electromagnetic, for rapid capture and to avoid wear of the parts. Thus, each docking station 11 as well as the carriage 31 advantageously comprise a controlled magnetic suction cup 510, 511 (i.e. an electromagnet), and the manufacturing head 12 comprises, on two opposite faces, a counter-plate 512 made of a magnetic material on which the magnetic field generated by the suction cup can result in a magnetic force.

[0076] In embodiments, the docking station 10 and the manufacturing head 12 on the one hand, and the carriage 31 and the head 12 on the other hand, may comprise means for guiding and controlling the alignment of the parts. For example, the docking station 11 may comprise a fork comprising at least two axes 520 adapted to be received in corresponding bores 521 of the manufacturing head 12 of a module. Conversely, the manufacturing head 12 of a module may also carry a fork whose axes are received in bores of the docking station. Similarly, the carriage 31 may comprise a fork comprising at least two axes 522 received in corresponding bores 523 of the print head, or vice versa.

[0077] In a preferred embodiment shown in [Fig. 7], the forks are carried by the docking station 11 and the carriage 31, and the manufacturing head 12 comprises through bores 521, 523 adapted to receive on one side the axes 520 of the fork carried by the docking station 11, and on the opposite side the axes 522 of the fork carried by the carriage 31. Indeed, in this case, one of the axes of the docking station and the carriage can be hollow, and an optical transmitter 524 / receiver 525 assembly can be installed in these hollow axes, which makes it possible to confirm the alignment of the carriage relative to the module when it comes to retrieve or deposit a print head in its docking station.For example, an infrared laser diode 524 may be positioned at the bottom of the hollow shaft of the docking station, and an infrared photodiode 525 may be positioned at the bottom of the hollow shaft opposite on the carriage 31, with detection of light from the diode by the photodiode confirming alignment of the carriage 31, the head, and the docking station.

[0078] Each manufacturing head 12 also comprises, on two opposite faces, electrical contacts (not shown) adapted to cooperate with electrical contacts 531, 532 on the one hand of the docking station and on the other hand of the carriage 31, these electrical contacts making it possible to electrically power, respectively by the docking station 11 or by the carriage 31, components contained in the manufacturing head 12. For example, in the case of a fused wire deposition printing module 10, the manufacturing head 12, hereinafter called the print head, comprises a heating element for melting the wire, and this heating element is electrically powered by the electrical contacts. The carriage 31 is connected to the main controller 41, for example by a wired connection, for reception instructions from the main controller 41 to move the manufacturing head 12, but also to transmit control instructions for the manufacturing head 12. In embodiments, and as shown schematically in [Fig.l], the manufacturing heads 12 of certain manufacturing modules may also comprise an electronic card comprising a controller 129, which is configured to receive instructions and to control electronic components in accordance with the instructions received, in particular by applying control parameters appearing in the instructions (for example: fan speed, heating temperature, etc.).Where appropriate, the electrical contacts of the manufacturing heads 12, docking stations 11 and the mobile carriage 31 are also adapted to allow the transmission of instructions, either from the docking station 11 or from the main controller 41 via the carriage, depending respectively on whether the manufacturing head is connected to the docking station or to the carriage.

[0079] Considering a docking station of a manufacturing module 10, the means of coupling to a module head, i.e. magnetic, mechanical and / or electrical coupling are arranged on a face of the docking station different from, and advantageously opposite to, the face carrying the mechanical and electrical connectors allowing the docking station to be mounted on the module location of the machine frame.

[0080] With reference to [Fig. 8], the carriage 31 comprises at least one motor 311 and a coupling member 312, typically a dog clutch, with an output shaft of the motor. Certain heads 12 of manufacturing modules 10, depending on their function, may comprise moving parts that can be driven by a motor, and in this case they advantageously comprise a coupling member adapted to cooperate with that 312 of the carriage 31 to be able to ensure that parts of the head are driven by the motor of the carriage. In this case also, and with reference to [Fig. 9], the docking station 11 of the module may also comprise a motor 111 and a coupling member 112, and an opposite face of the head of the module also comprises a coupling member (not shown) adapted to cooperate with that of the station.Thus, the implementation of moving mechanical parts of the manufacturing head 12 can be ensured by the docking station 11 or by the carriage 31, depending on whether the manufacturing head 12 is assembled to one or the other.

[0081] With reference to Figures 8 and 2, in an embodiment in which the machine 1 comprises two alignments 26 of locations 25 of parallel modules arranged on either side of the support plate 24, the mobile carriage 31 has a symmetrical configuration making it possible to couple with a manufacturing head 12 of the modules 10 of the two alignments. In this case, the mobile carriage 31 comprises two motors 311 and comprises, on two opposite faces, in the direction X, that is to say the faces which come opposite the heads 12 of the manufacturing modules, the elements coupling elements described above, ie magnetic suction cup 511, fork or bores, electrical connectors 532, motor coupling member 312. The optical sensor mentioned above can be positioned in the center of the carriage. The carriage 31 can also include encoders to detect the position of the motors as well as fans for cooling each motor and cooling the deposited material, if applicable.

[0082] With reference to Figures 9 and 10, embodiments of a fused filament deposition printing module 10 will now be described. In addition to the preceding description concerning any type of manufacturing module, the print head 12 of a fused filament deposition printing module comprises a nozzle 120, the diameter of which is constant and determined, and a heating element 121 for melting the filament before depositing it. In addition, the docking station 11 is configured to supply the print head 12 with filament from a spool 13 of filament. In this respect, the modular machine 1 comprises at least as many locations for spools 13 of filament as locations for manufacturing modules, the locations for the spools preferably being positioned under the locations of the modules.Some of these locations may be equipped for conditioning filament spools by temperature and humidity control. As shown in [Fig. 10], this configuration allows the filament to pass through an internal channel 113 provided for this purpose in a docking station 11 of a printing module 10, the filament entering the channel at a lower wall 114 of the docking station, and emerging from the docking station at an upper wall 115, where it is supported by a flexible guide rod 116 mounted on the docking station, this guide rod ensuring that the filament does not fall onto the printing area and does not form an obstacle in the path of the carriage or a manufacturing head 12.The dimensions of the guide rod are calculated to allow all parts of the working area of the support plate 24 to be reached, without exerting a restoring force which would be too great and which could hinder the precision of the head.

[0083] The filament is then introduced into an internal channel 122 of a print head 12, for example at an upper face 123 of the head, where it is conveyed to the nozzle arranged on a lower face 124 of the head, facing the support plate 25.

[0084] The manufacturing machine 1 also comprises a tray 14 for recovering the filament leaders or remnants arranged below the module locations. This tray can be interposed between the module locations 10 and the reel locations 13, while maintaining a passage for a filament between each reel location and each module location.

[0085] The docking station 11 of the printing module 10 is configured to supply the printing head 12 with filament. In this regard, and with reference to [Fig. 9], it comprises a motor 111 and a drive device 117 for the filament driven by the motor. Advantageously, the same motor drives the coupling member 112 and the drive device 117. This drive device 117 can be disengaged once the filament is loaded into the printing head.

[0086] Furthermore, the docking station 11 is configured to monitor a set of parameters relating to the filament and / or to the consumption of filament by the print head 12, and in this regard to comprise one or more sensors. In embodiments, the docking station comprises at least one sensor, for example an optical sensor 118, adapted to detect the filament, and to detect a break or an absence of filament. The docking station may also comprise an encoder 119 adapted to measure a length of unwound filament. The secondary controller 110 of the docking station is configured to communicate to the main controller 41 the length of filament consumed measured by the encoder, as well as alerts if an event of the break or absence of filament type is detected.The main controller 41 can, upon receiving an alert about a break or absence of filament, interrupt a manufacturing process in progress (in particular by sending to the print head 12, via the mobile carriage, instructions to stop manufacturing) and produce an alert on the human-machine interface intended for the operator. The main controller 41 is also configured to compare the length of filament consumed measured by the encoder with a theoretical length which is determined according to the geometry of the part to be produced, and generate an alert in the event of inconsistency between the two.

[0087] The print head 12 also comprises a filament drive device 125, which is driven either by the docking station motor or by the carriage motor, depending on whether the print head is mounted on one or the other, by means of the coupling members provided for this purpose and described above. The heating device 121 is interposed between the drive device and the nozzle 120, making it possible to melt the filament at the time of its deposition.

[0088] Advantageously, the docking station 11 of a fused filament deposition printing module 10 is also adapted to carry out the preheating and preloading of a filament in the head in masked time, that is to say during the operation of another manufacturing module, in preparation for the operation of the printing module. Thus, when the machine 1 implements a manufacturing sequence involving the operation, successively, of several manufacturing modules 10 including a fused filament deposition printing module, the main controller 41 is configured to command the secondary controller 110 of the docking station 11 of the printing module 10 this preheats and precharges during operation of a previous manufacturing module in the sequence.

[0089] The docking station 11 of certain manufacturing modules, and in particular fused deposition printing modules, may also be configured to clean the head so as to prevent residual material from being deposited on the part being manufactured. The docking station may in this respect comprise a cleaning device (not shown), static or not, motorized or not, which is configured to clean the head when the latter is replaced by the mobile carriage in the docking station or when it is recovered by the mobile carriage for use.

[0090] Like all manufacturing module docking stations, the docking station of a printing module is configured to communicate configuration information to the main controller during an initialization phase of the module. In this case, this configuration information may comprise a set of operating parameters of the module, comprising for example a set temperature for melting the filament of the module, a printing speed, a nozzle diameter, a fan speed, a waiting temperature, and a heating time, etc. From the configuration information transmitted by the secondary controllers 110 of the docking stations, and a description of a part to be manufactured, the main controller 41 is configured to generate a sequence of instructions for manufacturing the part.

[0091] When mounting a manufacturing module on the frame, in addition to transmitting configuration information to the main controller, a calibration of the position of the module manufacturing head, in position on the docking station, may be necessary to ensure that the carriage can move directly into the correct position to retrieve the module head. This position calibration includes a calibration along the two axes X, Y, the position in Z being fixed by the geometry of the machine. This calibration in X and Y can be implemented as follows: - First, a first Y calibration can be performed by scanning the carriage along the Y axis in front of the module, using the optical transmitter / receiver described above. The Y position of the head is determined when the carriage's optical receiver detects the docking station's transmitter. - Then, the X calibration is obtained by electrical contact. The machine positions the carriage at the Y position previously determined in front of the module head, and moves the carriage until electrical contact is achieved. The X position is then determined as that representing the compression to be achieved to ensure contact.

[0092] Additional calibration may be implemented for certain manufacturing modules. For example, the X and Y position of a nozzle relative to the head Since the printing position is not necessarily the same for all printing modules, this position can be determined by printing a test pattern and using the carriage's image sensor 310 to determine the coordinates of this printed pattern, and deduce the nozzle position from it. Other tools such as a laser tool, an engraving tip or a writing module can be subject to a similar calibration, but having previously installed an additional coating on the support plate so as not to leave a lasting mark on it.

[0093] The modular machine described above therefore allows the implementation of part manufacturing processes involving the successive intervention of various tools, i.e. comprising at least two manufacturing steps involving two different manufacturing modules. Between each manufacturing step, the carriage returns the manufacturing head used to the corresponding docking station and then recovers the manufacturing head necessary for the implementation of the following step.

[0094] By way of non-limiting example, a sequence for manufacturing an object may comprise: - a first printing step by depositing molten wire with a first printing module, for example of a first color, material, and / or a first printing diameter, - a second printing step by deposition of molten wire with a second printing module, for example of a second color, material, and / or a second printing diameter, - a third stage of engraving certain areas of the part, with an engraving module, - A fourth control step with a dimensional measurement module.

[0095] List of digital references: - 1: Modular machine - 10: Module - 11: docking station - 110: secondary controller - 111: engine - 113: internal channel - 114: lower wall - 115: upper wall - 116: guide rod - 117: filament drive device - 118: optical sensor - 119: encoder - 12: manufacturing head 120: nozzle 121: heating element 122: internal channel 123: upper face 124: lower face 125: filament drive device 129: controller 13: coil 14: filament collection bin 20: built 21: pregnant 22: peripheral wall 220: opening 23: upper wall 24: support plate 25: module location 250: mechanical connector 251: electrical connector 252: electronic card, 253: additional connector 26: Location alignment 30: moving device 31: mobile trolley 310: image sensor 311: engine 312: coupling member 32: arms 320: longitudinal piece 321: end piece 322: longitudinal housing 323: longitudinal rod 324: guide pulley 325: pebble 326: end piece amount 327: end piece base 33.33': belt 34: belt drive motor 35: rail 40: computer 41: Main controller 42: memory 43: User interface 510, 511: magnetic suction cup 512: magnetic counterplate 520, 522: fork axles 521, 523: bores 524: optical transmitter 525: optical receiver 531, 532: electrical contacts

Claims

Claims

1. Modular machine (1) for manufacturing objects by addition, subtraction or transformation of material, comprising: - a frame (20), - a support plate (24) for an object to be manufactured, - at least one manufacturing module (10), each manufacturing module comprising a docking station (11) and a manufacturing head (12) removable relative to the docking station, - a device (30) for moving a manufacturing head (12) relative to the support plate (24), and - a main controller (41), configured to control the moving device, characterized in that each manufacturing module docking station (11) comprises a secondary controller (110), the frame comprises a plurality of locations (25) for manufacturing modules,and in that each module docking station (11) and each slot (25) are adapted to allow a docking station to be removably mounted in any of the slots in the rack, and to establish communication between the secondary controller of the docking station and the primary controller when the docking station is mounted in a slot in the rack.,

2. Modular machine according to claim 1, wherein each docking station of a manufacturing module comprises a memory storing configuration information of the manufacturing module, and the secondary controller is configured to transmit said configuration information to the primary controller during an initialization phase of the manufacturing module.

3. Modular machine (1) according to claim 1 or 2, wherein each docking station (11) comprises a presence sensor of the removable manufacturing head, and the secondary controller (110) is configured to communicate a presence or absence status of the removable manufacturing head to the primary controller (41).

4. Modular machine (1) according to one of the preceding claims, wherein the moving device (30) comprises a movable carriage (31) in a plane parallel to the support plate (24), the carriage comprising mechanical and electrical connection means (522, 532) with a manufacturing head, a motor (311), and a dog clutch (312) driven by the motor.

5. Modular machine (1) according to one of the preceding claims, comprising two alignments (26) of locations (25) of the manufacturing modules, arranged parallel to each other, on either side of the support plate (24) of the object to be manufactured.

6. Modular machine (1) according to the preceding claim, in which the device (30) for moving a manufacturing head (12) comprises a movable arm (32) in translation in a direction parallel to the alignments (26) of the locations of the modules, and a movable carriage (31) in translation in the arm, in a direction perpendicular to the direction of movement of the arm, the carriage (31) comprising removable gripping means (511) for a head (12) for manufacturing a module, arranged on either side of the carriage in its direction of movement.

7. Modular machine (1) according to one of the preceding claims, in which the device (30) for moving a manufacturing head (12) comprises a movable carriage (31) in a plane parallel to the support plate (24), and at least one moving belt (33, 33') of the movable carriage (31) defining a closed contour, and the locations (25) for the manufacturing modules are located inside the contour defined by the belt.

8. Modular machine (1) according to claim 7, wherein the moving device (30) comprises two superimposed moving belts (33,33') moving in opposite directions.

9. Modular machine (1) according to one of the preceding claims, comprising at least one fused filament deposition printing module, the docking station of which is configured to supply the head with filament, and the head comprises a wire heating device (121), and a deposition nozzle (120).

10. Modular machine (1) according to claim 9 in combination with claim 4, wherein the head (12) of the fused deposition printing module further comprises a drive mechanism (125) capable of being driven by the motor of the carriage via the dog clutch (312), when the carriage (31) is connected to the head (12).

11. Modular machine (1) according to one of claims 9 to 11, in which the secondary controller (110) of the docking station (11) of the fused filament deposition printing module is configured to transmit to the main controller (41) information relating to a length of filament consumed and / or an alert relating to an event such as breakage or absence of filament.

12. Modular machine (1) according to one of claims 9 to 12, in which the main controller (41) is configured to control the implementation of a manufacturing sequence involving the operation, successively, of a first manufacturing module and the fused deposition printing module, and the docking station of the fused deposition printing module is further configured, upon receipt of instructions from the main controller, to preheat and preload the print head with filament, during the operation of the first manufacturing module.

13. Modular machine (1) according to one of the preceding claims, further comprising at least one manufacturing module (10) from the following group: - Writing module, - Milling module - Liquid deposition module, - Cutting module, - Laser module, - Gripping and deposition module, - Material injection module, - Dimensional measurement module, - Engraving module, - Smoothing module, - Continuous fiber deposition module, - Resin deposition and polymerization module.

14. A manufacturing or control module (10) adapted for use in a machine according to any preceding claim, the manufacturing module (10) comprising a docking station (11) and a manufacturing head (12) removable from the docking station, wherein the docking station (11) comprises a controller (110), and connection means adapted to enable it to be mounted on the frame of the machine in a removable manner.

15. Manufacturing or control module (10) according to claim 14, wherein the docking station (11) comprises a motor (111) and a coupling member (112) with an output shaft of the motor, and the manufacturing head (12) comprises moving mechanical parts and a coupling member adapted to cooperate with the coupling member of the docking station and to drive the moving mechanical parts into motion once the coupling has been achieved.

16. Manufacturing or control module (10) according to one of claims 14 to 15, for fused filament deposition printing, in which the docking station (11) is configured to supply the head (12) with filament, and the head (12) comprises a filament heating device (121) and a deposition nozzle (120).

17. Module (10) according to the preceding claim, in which the docking station (11) further comprises at least one sensor adapted to detect a break or an absence of filament, and / or to measure a length of filament consumed.

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