Forming method

Abstract

To provide a forming method for efficiently forming a structure.SOLUTION: A laminated product 410 is formed, the product being laminated by stacking layers formed of a molding material discharged from a nozzle as the nozzle is moved. In this case, a first region 411 having an inclined part and a second region 412 coupled to the first region 411 are formed. The laminated product 410 having the inclined part is formed by the second region 412 disposed in an upper part by disposing the first region 411 in a lower part, and the first region 411 is masked.SELECTED DRAWING: Figure 4

Description

[Technical field]

[0001] The present disclosure relates to a method for forming a structure by layering a forming material ejected from a moving nozzle. [Background technology]

[0002] When forming a three-dimensional structure such as a building, a three-dimensional (3D) printer may be used. In this 3D printer, each layer is formed by moving the nozzle while discharging material from the nozzle. Then, each layer is stacked to form a structure having a three-dimensional shape. A structure forming system for forming a structure having a side surface of a desired shape using a three-dimensional printer has been considered (see, for example, Patent Document 1). The structure forming system described in this document includes a nozzle that discharges mortar that forms the structure, a robot arm, a side member, and a control device. The side member is placed along the movement path of the nozzle while maintaining a position at a predetermined distance from the movement path of the nozzle. The predetermined distance is a distance that allows the mortar discharged from the nozzle to contact the abutting surface of the side member and to fill the gap at the end face of the lower mortar layer.

[0003] 8(a), a structure 500 having an inclined shape may be constructed. Such a shape can also be formed by a 3D printer. As shown in FIG. 8(b), in the upper layer portion, a structure 501 having a stepped inclined shape can be formed by making each floor smaller using a 3D printer.

[0004] Also, as shown in FIG. 8(c), by changing the layer thickness of each layer in the upper layer using a 3D printer, a structure 502 having an inclined shape can be formed. [Prior art documents] [Patent documents]

[0005] [Patent Document 1] JP 2018-69661 A Summary of the Invention [Problem to be solved by the invention]

[0006] In the structure 501 shown in Fig. 8(b), a smooth shape cannot be realized because it has a stepped shape. Also, in order to form the structure 502 shown in Fig. 8(c), it is necessary to change the layer thickness in the 3D printer. Since it is difficult to control the layer thickness in the 3D printer, it is difficult to realize a smooth shape. [Means for solving the problem]

[0007] The method for solving the above problem forms a layered structure by stacking layers formed of a molding material discharged from a nozzle while moving the nozzle. Here, a first region having an inclined portion and a second region connected to the first region are formed, and the first region is positioned below, so that the second region positioned above forms a structure having the inclined portion and shields the first region. Effect of the Invention

[0008] According to the present invention, a structure can be formed efficiently. [Brief description of the drawings]

[0009] [Figure 1] FIG. 2 is an explanatory diagram of the structure of a formation support system in an embodiment. [Diagram 2] FIG. 2 is an explanatory diagram of a hardware configuration according to an embodiment. [Diagram 3] FIG. 2 is an explanatory diagram of a processing procedure according to an embodiment. [Figure 4] 4A to 4D are explanatory views of a forming method in an embodiment, in which (a) is an explanatory view of forming a base, (b) is an explanatory view of forming a laminate, (c) is an explanatory view of placing the laminate, and (d) is an explanatory view of fixing the laminate. [Diagram 5]1A is an explanatory diagram of a forming method in an embodiment, in which (a) is an explanatory diagram of a base, (b) is a laminate on the base, and (c) is an explanatory diagram of a laminate with the base removed. FIG. [Figure 6] 10A and 10B are explanatory views of a production procedure in another example, in which FIG. 10A shows a base and FIG. 10B shows a laminate on the base. [Figure 7] 13A and 13B are explanatory diagrams of a manufacturing procedure in another example, in which (a) is a laminate with a changed lamination thickness, and (b) is an explanatory diagram of a structure in which the laminates are arranged. [Figure 8] 1A is an explanatory diagram of a structure having an inclined portion; FIG. 1B is an explanatory diagram of a structure in which the inclined portion is formed in a stepped shape; and FIG. 1C is an explanatory diagram of a structure in which the layer thickness is changed. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0010] Hereinafter, one embodiment embodying the forming method will be described with reference to FIGS. 1, in this embodiment, a 3D printer 10 is used. The 3D printer 10 is controlled by a control device 20.

[0011] (Hardware configuration example) FIG. 2 shows an example of the hardware configuration of an information processing device H10 that functions as the control device 20 or the like.

[0012] The information processing device H10 includes a communication device H11, an input device H12, a display device H13, a storage device H14, and a processor H 15. Note that this hardware configuration is an example, and the information processing device H10 may include other hardware.

[0013] The communication device H11 is an interface that establishes a communication path with other devices and transmits and receives data. The input device H12 is a device that accepts input from a user, etc. The display device H13 is a device that displays various types of information.

[0014] The storage device H14 is a storage unit that stores data and various programs for executing various functions of the control device 20. The processor H15 uses programs and data stored in the storage device H14 to control each process in the control device 20. Examples of the processor H15 include a CPU and an MPU.

[0015] (3D Printer 10 Configuration) As shown in FIG. 1, a 3D printer 10 includes a nozzle 11 as a discharge unit, and a robot arm 15.

[0016] The nozzle 11 has a discharge port 11a that opens at its tip. In this embodiment, the discharge port 11a faces downward. An end of a hose 12 is connected to the end of the nozzle 11 opposite to the discharge port 11a. The hose 12 is connected to a pressure pump 13. Mortar supplied to the nozzle 11 through the hose 12 is discharged downward from the discharge port 11a by the pressure of the pressure pump 13.

[0017] A robot arm 15 is attached to the nozzle 11 via an attachment part 14. The nozzle 11 is supported by the robot arm 15 and moves horizontally and vertically in accordance with the movement of the robot arm 15. The movement of the robot arm 15 is controlled by instructions from a control part 21 of the control device 20. The control part 21 of this embodiment controls the robot arm 15 so that the direction of mortar discharge from the nozzle 11 is always downward even during movement.

[0018] (Configuration of control device 20) The control device 20 includes a control unit 21 that executes a structure formation process. Therefore, the control unit 21 functions as a stacking management unit 211, a movement control unit 212, and a discharge amount control unit 213 by executing a structure formation program stored in the storage unit.

[0019] The stacking management unit 211 executes a process of managing the path and height of the mortar to be stacked. The stacking management unit 211 counts the number of stacked layers L1, stores the current number of stacked mortar layers, and stops the movement of the nozzle 11 when the final number of stacked layers of the structure is reached.

[0020] The movement control unit 212 executes a process for controlling the movement of the robot arm 15 that moves the nozzle 11 according to the path. The discharge amount control unit 213 executes a process of controlling the mortar pressure pump 13 to control the amount of mortar discharged from the nozzle 11 .

[0021] Discharge path data of the nozzle 11 that forms the structure is recorded in the discharge path storage unit 22. This discharge path data is recorded when the path and the path discharge width are determined. The discharge path data includes data on the structure identifier, the path for each layer identifier, and the path discharge width.

[0022] The structure identifier data area stores data on an identifier for identifying each structure. In the layer identifier data area, data on the number of hierarchical levels of each layer from the start point to the end point in a single line is recorded.

[0023] The path data area records the three-dimensional coordinates of the path of the nozzle 11 of the 3D printer 10 at this level. In the path discharge width data area, data on the width of the path portion formed by the mortar discharged from the nozzle 11 moving in one direction is recorded.

[0024] (Formation process) Next, the formation process will be described with reference to FIGS. As shown in FIG. 3, first, a pedestal is placed (step S11). In this embodiment, a pedestal having a different shape depending on the layer is formed. For example, a 3D printer 10 is used to form a pedestal having a step-like difference (riser) by making the upper layer smaller than the lower layer. In the pedestal having a step-like difference (riser), the ratio between the height of each step (riser) and the length of the flat surface (tread) is set to be constant. The inclination angle is determined by this ratio. Furthermore, the flat surface is formed to a size that can ensure a discharge path. Furthermore, the height of each step is set to be approximately an integer multiple of the layer thickness.

[0025] As shown in Fig. 4(a), a 3D printer 10 is used to form a base 400 on a ground surface G1 using a discharge path in which an upper layer is smaller than a lower layer. A release layer R1 is then formed on the upper surface of the formed base 400 by applying a release agent or applying masking tape. This release layer R1 allows the base 400 to be separated from the laminate formed on the base 400.

[0026] Next, an upper layer laminate is formed (step S12). Here, the laminate is formed on the base 400 using the 3D printer 10. As shown in Fig. 4(b), the 3D printer 10 is used to fill in the step shape of the upper layer of the base 400 with lamination, thereby forming a first region 411 as an inclined portion. A second region 412 is laminated on the first region 411 with the stepped shape embedded therein, with each layer being of a desired size, thereby forming a laminate 410. In this case, the size of each layer is determined according to the size and inclination angle of the structure.

[0027] Next, the pedestal is removed (step S13). Specifically, the upper layer, the laminate 410, is lifted, and the laminate 410 and the pedestal 400 are separated at the peeling layer R1. Then, the remaining pedestal 400 is removed. 4(c), the laminate 410 separated from the base 400 is placed on the ground surface G1. In this case, the first region 411 becomes the lower layer region.

[0028] Next, the laminate is fixed (step S14). Here, a part of first region 411, which is a lower region of laminate 410, is buried in the ground, thereby fixing the part of first region 411. In this case, the buried part of first region 411 is shielded from the surroundings. Specifically, as shown in Fig. 4(d), the laminated material 410 is fixed by burying a part of the first region 411 at a position lower than the ground surface G1. In this case, the laminated material 410 is buried so that the stepped portion of the first region 411 is lower than the ground surface G1, with the second region 412 exposed. In this case, for example, the laminated material 410 is placed in a previously excavated area, and then backfilled. Alternatively, the laminated material 410 may be buried by filling the area with soil.

[0029] (Specific examples) An example of a specific shape of the base and the laminate will be described with reference to FIG. As shown in Fig. 5(a), a stepped base 401 is formed using a 3D printer 10. In this case, the discharge path of one layer is doubled to form one layer in one stroke. Furthermore, a release layer R1 is provided on the upper surface of the base 401.

[0030] 5(b), the 3D printer 10 is used to form a first region 411 so as to fill in the step of the base 401. In this case as well, the discharge path of the first layer is doubled, so that the first layer is formed in one stroke.

[0031] 5(c), the base 401 is removed by the peeling layer R1 to obtain a laminate 410. Since the lower layer region of this laminate 410 has a stepped shape according to the shape of the base 401, the upper layer region can be tilted by placing this lower layer region on a horizontal plane.

[0032] (action) By providing a laminate 410 having a stepped shape in the lower layer region, the upper layer region is inclined.

[0033] According to this embodiment, the following effects can be obtained. (1) In this embodiment, a pedestal is placed (step S11), whereby a laminate 410 having a staircase shape in a first region 411 can be formed. (2) In this embodiment, a release layer R1 is formed on the upper surface of the base 400. This makes it possible to easily separate the laminate 410 from the base 400 in removing the base (step S13).

[0034] (3) In this embodiment, the upper layer laminate is formed (step S12). Since the thickness of each layer is the same, the lamination of the mortar can be easily controlled. (4) In this embodiment, the laminate is fixed (step S14). This makes the staircase shape of the first region 411 invisible from the outside, and allows the second region 412, which becomes the upper layer region, to have a smooth slope.

[0035] This embodiment can be modified as follows: This embodiment and the following modifications can be combined with each other to the extent that there is no technical contradiction. In the above embodiment, a pedestal is placed (step S11). Here, the pedestal 400 is formed using the 3D printer 10. The pedestal 400 does not have to be made of mortar as long as it has the strength to support the laminated body 410. For example, the pedestal may be formed by a 3D printer using resin.

[0036] In the above embodiment, a pedestal is placed (step S11). Here, the pedestal 400 is formed using the 3D printer 10. If a pedestal having a step is used, the formation method is not limited to using the 3D printer 10.

[0037] 6(a), a plurality of plates P1 may be stacked to form the base 402. In this case as well, a release layer is provided on the exposed upper surface of each plate P1. Then, as shown in FIG. 6(b), a laminate 410 is formed so as to fill in the step formed by the plate P1.

[0038] The inclination angle of the laminate is determined by the step height of the pedestal 402 and the size of the flat surface, so as long as the inclination angle is the same, it can be used for laminates of various shapes, allowing the base to be used effectively.

[0039] In the above embodiment, the laminate 410 having an inclined portion is formed using the base 400. Alternatively, a region having a different laminate thickness may be provided in the lower layer region. As shown in Fig. 7(a), a 3D printer 10 is used to form a laminate 420 having a lower layer region 421 and an upper layer region 422. In this case, in the lower layer region 421 as an inclined portion, a slope is created by changing the height of the nozzle 11 and the layer thickness in one layer. Then, in the upper layer region 422, each layer is laminated at a constant layer thickness while changing the height of the nozzle 11.

[0040] Then, as shown in FIG. 7(b), a plurality of laminates 420 are aligned and positioned so that the layers of the upper layer region 422 are connected. Thereafter, the lower layer region 421 is buried below the ground surface G1. As a result, on the ground surface G1, a structure made up of laminated bodies 420 in which each story is connected can be formed in the inclined shape of the upper layer region 422.

[0041] In the above embodiment, the lower region of the laminate is buried in the ground to shield the lower region. The method of shielding is not limited to burying the lower region in the ground. The lower region may be shielded by providing a wall or the like around the lower region. In the above embodiment, the second region 412 is stacked on top. Here, depending on the inclination when the first region 411 is placed on a horizontal surface, the layers may be stacked with a shift so that the end face of the first region 411 becomes an extended surface when the stack is fixed.

[0042] Next, the technical ideas that can be understood from the above embodiment and other examples will be described below. 3. The method according to claim 2, further comprising the step of: (a) removing the pedestal after the first region and the second region are formed, thereby tilting the first stacked portion.

[0043] (b) The method according to claim 2 or (a), characterized in that the base is formed from a molding material ejected from the nozzle. (c) forming a first structure and a second structure having a second region with the same lamination thickness; The formation method according to claim 1, 2, (a) or (b), characterized in that the first structure and the second structure are adjacent to each other and the arrangement positions are adjusted so that the second region of the first structure and the second region of the first structure are connected at different layers. [Explanation of symbols]

[0044] L1...layer, 10...3D printer, 11...nozzle, 11a...discharge outlet, 12...hose, 14...mounting section, 15...robot arm, 20...control device, 21...control section, 211...stacking management section, 212...movement control section, 213...discharge amount control section, 22...discharge path memory section, 411...first area, 412...second area.

Claims

1. 1. A method for forming a layered structure by stacking layers of a modeling material dispensed from a nozzle while moving the nozzle, comprising: forming a first region having an inclined portion and a second region connected to the first region; By disposing the first region below, a structure having the inclined portion is formed by the second region disposed above; The method further comprises shielding the first region.

2. The method according to claim 1 , wherein the first region is formed by stacking layers on a stepped pedestal having a step so as to fill the step.

3. The method according to claim 1 , further comprising forming the first region having a slope formed by changing a thickness of the laminate.

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