Forming method and forming device

Abstract

To provide a forming method and a forming device for forming a structure by lamination.SOLUTION: In a forming method, a laminated structure is formed by stacking layers L1 formed of a shaping material discharged from a nozzle 11 in a lamination path, by using a 3D printer 10 including: the nozzle 11 for discharging the shaping material; a robot arm 15 for moving the nozzle 11 according to the lamination path; and a reinforcing material supplying device 30 that delivers a reinforcing material with the notches to the shaping material in the nozzle 11. Before the shaping material is discharged, a reinforcing shaping material is generated by cutting and mixing steel wires W1 into flowing mortar M1, and the reinforcing shaping material is discharged from the nozzle 11 to form a structure.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present disclosure relates to a method and an apparatus for forming a structure by stacking 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, a nozzle is moved while a material is ejected from the nozzle to form each layer. 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 is being considered (for example, see Patent Document 1).

[0003] Furthermore, a 3D printer may be used to form a structure in one stroke (see, for example, Patent Document 2). The formation support system described in this document includes a control unit that generates a lamination path along which a nozzle that ejects mortar moves. The control unit generates divided regions that divide the planar shape of the laminated part in the width direction of the laminated part. Then, a lamination path that connects all of these divided regions in one stroke is generated.

[0004] Furthermore, in order to improve the tensile strength and bending strength of mortar, etc., a technique using fiber-reinforced mortar mixed with short fibers has also been considered (for example, see Patent Document 3). In the technique described in this document, fiber-reinforced mortar with sizes of 100 to 130 mm and 150 to 190 mm is used during extrusion lamination by a 3D printer.

[0005] Furthermore, technology for improving the bonding strength between layers has also been studied (see, for example, Patent Document 4). In the technology for constructing a laminated structure described in this document, a reinforcing material made of fiber material or steel wire material cut to an appropriate length in advance is blown by compressed air onto the upper surface of the printed layer that constitutes the shell wall in sequence. [Prior art documents] [Patent documents]

[0006] [Patent Document 1] JP 2018-69661 A [Patent Document 2] JP 2023-64588 A [Patent Document 3] JP 2022-124859 A [Patent Document 4] Patent No. 6993794 Summary of the Invention [Problem to be solved by the invention]

[0007] By adding reinforcing materials, it is possible to strengthen the laminated structure. However, in the technology of Patent Document 3, there is a possibility that the pump that discharges the mortar or the tube that transports the mortar may be clogged by fibers. In addition, in the technology of Patent Document 4, in order to embed the reinforcing body in the layer, the reinforcing body made of fiber material or steel wire material cut to an appropriate length in advance is sprayed by compressed air onto the upper surface of the print layer that constitutes the shell wall. In this case, it was difficult to control the amount of fiber because the fiber scatters. [Means for solving the problem]

[0008] A forming method for solving the above problem uses a forming device including a nozzle for ejecting a molding material, a moving device for moving the nozzle according to a lamination path, and a reinforcing material supplying device for feeding a reinforcing material to the molding material in the nozzle. A laminated structure is then formed by stacking layers formed of the molding material ejected from the nozzle along the lamination path. In this case, the reinforcing material supplying device generates a reinforcing molding material by cutting and mixing linear reinforcing material into the flowing molding material before ejecting the molding material, and ejects the reinforcing molding material from the nozzle to form the structure. Effect of the Invention

[0009] According to the present invention, a structure can be formed efficiently. [Brief description of the drawings]

[0010] [Figure 1] FIG. 2 is an explanatory diagram of a forming device according to an embodiment. [Diagram 2] FIG. 4 is an explanatory diagram of an insertion portion of a linear reinforcing material in the embodiment. [Diagram 3] FIG. 2 is an explanatory diagram of a hardware configuration according to an embodiment. [Figure 4] FIG. 2 is an explanatory diagram of a processing procedure according to an embodiment. [Diagram 5] 4A to 4C are explanatory diagrams of a forming method in the embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0011] Hereinafter, a specific embodiment of the forming method and forming device will be described with reference to FIGS. As shown in Fig. 1, in this embodiment, a 3D printer 10 is used to build a structure by stacking layers L1. The 3D printer 10 is controlled by a control device 20. The 3D printer 10 includes a reinforcing material supply device 30. In addition, a stacking path for operating the 3D printer 10 is generated by a design device 40.

[0012] (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.

[0013] The nozzle 11 has a discharge pipe 11a whose tip is open. In this embodiment, the discharge pipe 11a faces downward. An end of a hose 12 is connected to the end of the nozzle 11 opposite to the discharge pipe 11a. The hose 12 is connected to a pressure pump 13. Mortar M1 supplied to the nozzle 11 through the hose 12 is discharged downward from the discharge pipe 11a by the pressure of the pressure pump 13.

[0014] A robot arm 15 is attached to the nozzle 11 via an attachment portion 14. The nozzle 11 is supported by this robot arm 15 (moving device) and moves horizontally and vertically in accordance with the movement of this robot arm 15. The movement of the robot arm 15 is controlled by instructions from a control unit 21 of the control device 20. The control unit 21 of this embodiment controls the robot arm 15 so that the discharge direction of mortar M1 from the nozzle 11 is always downward even during movement.

[0015] In this embodiment, a steel wire piece Wd1 having a predetermined thickness and a predetermined length is added as a linear reinforcing material to the mortar M1. As shown in Fig. 2, a branch pipe 11b is provided on the discharge pipe 11a of the nozzle 11. This branch pipe 11b is connected to a region in the discharge pipe 11a where the mortar M1 flows linearly until it is discharged. The inner diameter d1 of this branch pipe 11b is slightly larger than the diameter of the steel wire W1 (linear reinforcing material) and is large enough for the steel wire W1 to slide inside the pipe. The steel wire W1 is supplied from the reinforcing material supply device 30 to the mortar M1 flowing inside the discharge pipe 11a through the branch pipe 11b.

[0016] The reinforcing material supplying device 30 includes a control unit 31, a feed roller 32, and a rotary blade 33. The control unit 31 controls the operations of the feed roller 32 and the rotary blade 33. The feed roller 32 feeds the steel wire W1 to the branch pipe 11b. The control unit 31 controls the rotation speed of the feed roller 32 to control the feed amount of the steel wire W1.

[0017] The rotary blade 33 performs a half cut by making a cut in the steel wire W1. By rotating the rotary blade 33, the blade tip comes into contact with the steel wire W1 at a predetermined cycle, and a cut is made at the contact point. The control unit 31 can adjust the interval of the cut in the steel wire W1 by changing the rotation speed of the rotary blade 33 according to the rotation speed of the delivery roller 32. The depth of the cut can be adjusted according to the positional relationship between the steel wire W1 delivered from the delivery roller 32 and the rotary blade 33. In this embodiment, the depth of the cut may be a depth at which the steel wire W1 is cut in the mortar M1 to become a steel wire piece Wd1 of a predetermined length. For example, the depth at which the steel wire W1 is cut by the mortar M1 flowing in the discharge pipe 11a may be a depth at which the steel wire W1 is almost cut.

[0018] The slit steel wire W1 is introduced into the discharge pipe 11a via the branch pipe 11b. Inside the discharge pipe 11a, the steel wire W1 is subjected to the discharge pressure of the mortar M1 and separated into steel wire pieces Wd1 at the slits and mixed with the mortar M1 to produce a reinforcing material.

[0019] (Hardware configuration example) FIG. 3 shows an example of the hardware configuration of an information processing device H10 that functions as the control device 20, the reinforcing material supply device 30, the design device 40, and the like.

[0020] 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.

[0021] 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.

[0022] The storage device H14 is a storage unit that stores data and various programs for executing various functions of the control device 20 and the reinforcing material supply device 30. The processor H15 uses the programs and data stored in the storage device H14 to control each process in the control device 20 and the reinforcing material supply device 30. An example of the processor H15 is a CPU or an MPU.

[0023] (Functions of the control device 20 and the design device 40) 1, 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.

[0024] The stacking management unit 211 executes a process for managing the path and height of the stacked mortar M1. The stacking management unit 211 counts the number of stacked layers L1, stores the current number of stacked layers of mortar M1, and stops the movement of the nozzle 11 when the final number of stacked layers of the structure is reached.

[0025] 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 discharge amount of the mortar M1 discharged from the nozzle 11 by controlling the pressure pump 13 for the mortar M1.

[0026] The lamination path data of the nozzle 11 that forms the structure is recorded in the lamination path storage unit 22. This lamination path data is recorded when the path and the path discharge width are determined. The lamination path data includes data on the structure identifier, the path for each layer identifier, the path discharge width, and information on whether or not addition is required.

[0027] 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.

[0028] 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 M1 discharged from the nozzle 11 moving in one direction is recorded. In the addition necessity information data area, data for determining whether or not the steel wire piece Wd1 is required to be added is recorded according to the path position.

[0029] The lamination path data recorded in the lamination path storage unit 22 is generated by a design device 40. The design device 40 generates the lamination path data from a 3D model generated by a three-dimensional CAD (Computer Aided Design).

[0030] (Formation process) Next, the formation process will be described with reference to FIG. 4 and FIG. As shown in FIG. 4, first, the design device 40 sets a route (step S11). Specifically, the design device 40 acquires design drawings of the structure to be formed. Next, the design device 40 acquires the shape of each layer to be stacked and the design width of each part. Next, the design device 40 divides the height of the structure by the floor height of the mortar M1 to generate the shape (nodes, links) of each layer and calculates the number of layers. Then, the design device 40 determines an arbitrary node as a starting point, and generates a route that travels from this starting point to all nodes via each link. In this case, it is assumed that the stacking path that forms one part (e.g., a wall) in one floor is stacked in one stroke by configuring it with a route that is adjacent to each other by doubling.

[0031] Next, the design device 40 sets the reinforcement area (step S12). Specifically, the design device 40 specifies a route for laminating the outside of the structure and a route for laminating the inside of the structure. Here, the route for laminating the inside of the structure is a route that forms an area enclosed in a narrow space of a predetermined volume or less by the walls that constitute the structure.

[0032] As shown in Fig. 5, one wall is formed using multiple routes on one floor (xy plane) of a structure. Specifically, one floor is formed in one stroke from position ST1 to position ST1 via route R11 → route R21 → .... In this case, when stacking the route R1i (white area) exposed to the outside, a setting is made such that no reinforcing material is added. On the other hand, when stacking the inner lot R2i (shaded area), a setting is made such that steel wire pieces Wd1 are added to the mortar M1.

[0033] Then, the design device 40 records the generated stacking path data in the stacking path storage unit 22 of the control device 20. This stacking path data includes the set addition necessity information. Next, the control device 20 forms a laminate (step S13). Here, the 3D printer 10 is used to form a structure using the lamination path recorded in the lamination path storage unit 22. In this case, the movement control unit 212 controls the movement of the robot arm 15 that moves the nozzle 11 according to the path. The discharge amount control unit 213 controls the pressure pump 13 for the mortar M1 to control the amount of mortar M1 discharged from the nozzle 11. In the case of an addition area according to the addition necessity information, the discharge amount control unit 213 controls the control unit 31 of the reinforcing material supply device 30 to add the steel wire pieces Wd1 to the mortar M1. In this case, the control unit 31 adjusts the rotation speed of the delivery roller 32 to adjust the amount of the steel wire pieces Wd1 to be mixed into the mortar M1. Furthermore, the control unit 31 adjusts the rotation speed of the rotary blade 33 according to the rotation speed of the delivery roller 32 to adjust the length of the steel wire pieces Wd1 to be mixed into the mortar M1 according to the incision position.

[0034] (Operation of the embodiment) Since the steel wire pieces Wd1 are added to the mortar M1 flowing inside the nozzle 11, the tensile strength and bending strength of the mortar M1 are improved, and cracks are suppressed.

[0035] According to this embodiment, the following effects can be obtained. (1) In this embodiment, the feed roller 32 of the reinforcing material supply device 30 feeds the steel wire W1 to the branch pipe 11b. This allows the steel wire pieces Wd1 to be mixed into the mortar M1 in the discharge pipe 11a. By changing the rotation speed of the feed roller 32, the amount of steel wire mixed into the mortar M1 can be adjusted.

[0036] (2) In this embodiment, the rotary blade 33 of the reinforcing material supply device 30 performs a half cut by making a cut in the steel wire W1. As a result, the steel wire W1 is dragged into the discharge pipe 11a and simultaneously cut into a fibrous form. By changing the rotation speed of the rotary blade 33, the cut position can be adjusted, and the length of the steel wire mixed into the mortar M1 can be adjusted.

[0037] (3) In this embodiment, the design device 40 generates stacking path data from a 3D model generated by three-dimensional CAD (Computer Aided Design). This allows the structure to be formed by the 3D printer 10.

[0038] (4) In this embodiment, the design device 40 sets a reinforcement region (step S12). This makes it possible to set a region where the steel wire piece Wd1 is added and a region where the steel wire piece Wd1 is not added in the lamination path.

[0039] (5) In this embodiment, the control device 20 forms a laminate (step S13). In this case, the laminate management unit 211 controls the reinforcing material supply device 30 to add the steel wire pieces Wd1 to the mortar M1 in the addition region based on the addition necessity information. This makes it possible to suppress the protrusion of the steel wire from the mortar M1 on the outside.

[0040] (6) In the present embodiment, the branch pipe 11b is connected to a region in the discharge pipe 11a where the mortar M1 flows linearly, thereby making it possible to suppress clogging of the steel wire pieces Wd1 in the discharge pipe 11a.

[0041] 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, the feed roller 32 of the reinforcing material supply device 30 feeds the steel wire W1 to the branch pipe 11b. The method of feeding the steel wire W1 is not limited to using the feed roller 32. For example, the steel wire W1 may be fed from the branch pipe 11b by using negative pressure generated by the flow of the mortar M1 in the discharge pipe 11a. Here, if the steel wire pieces Wd1 are not added, a locking mechanism for the steel wire W1 is provided. The steel wire W1 may also be fed by using ultrasonic vibration.

[0042] In the above embodiment, the design device 40 sets the reinforcement area (step S12). Specifically, the design device 40 identifies a route for stacking the outside of the structure and a route for stacking the inside of the structure. The setting of the reinforcement area is not limited to the inside or outside. It may be determined based on what is placed in the closed space. For example, if it is not desired for the steel wire to protrude within the space surrounded by the route R21 in FIG. 5, the design device 40 sets the route R21 so that the steel wire piece Wd1 is not added.

[0043] Also, the steel wire pieces Wd1 may be added to the area of ​​the structure that is not exposed to the outside, and the steel wire pieces Wd1 may not be added to the area of ​​the structure that is exposed to the outside. For example, one wall is formed into one story by drawing three or more layers in one stroke. The steel wire pieces Wd1 may be added to the intermediate lamination path. Also, the steel wire pieces Wd1 may not be added to the area that is covered with a coating material.

[0044] In the above embodiment, the discharge pipe 11a is provided with the branch pipe 11b. The connection form (position, number, etc.) of the branch pipe 11b is not limited. In the above embodiment, the rotary blade 33 performs a half cut by making a cut in the steel wire W1. The cutting method is not limited as long as the steel wire pieces Wd1 obtained by dividing the steel wire W1 can be sequentially mixed into the mortar M1. In the above embodiment, the control unit 31 controls the amount of steel wire W1 delivered by controlling the rotation speed of the delivery roller 32. Here, the amount of mortar M1 delivered from the nozzle 11 by the pressure pump 13 may be acquired, and the rotation speed of the delivery roller 32 may be controlled in accordance with this amount of mortar M1. Here, when the amount of mortar M1 delivered is large, the rotation speed of the delivery roller 32 is increased to increase the amount of steel wire pieces Wd1 mixed in.

[0045] Next, the technical ideas that can be understood from the above embodiment and other examples will be described below. The method according to claim 1 or 2, characterized in that (a) the linear reinforcement material with the incisions is cut within the flow of the shaped material. (b) The method according to claim 1, 2 or (a), characterized in that the amount of reinforcing material mixed into the reinforcing molding material is changed in the reinforcing material supply device. The forming method according to claim 1, 2 or (a), characterized in that (c) the interval between the cuts is changed in the reinforcing material supplying device.

[0046] (d) the method according to claim 2, characterized in that an area of ​​the structure that is not exposed to the outside is formed by the first lamination path, and an area of ​​the structure that is exposed to the outside is formed by the second lamination path. [Explanation of symbols]

[0047] M1...mortar, Wd1...steel wire piece, 10...3D printer, 11...nozzle, 11a...discharge pipe, 12...hose, 14...mounting unit, 15...robot arm, 20...control device, 21...control unit, 211...stacking management unit, 212...movement control unit, 213...discharge amount control unit, 22...stacking path memory unit, 30...reinforcement material supply device, 31...control unit, 32...feed-out roller, 33...rotary blade, 40...design device.

Claims

1. A nozzle for discharging a molding material; A moving device that moves the nozzle according to a lamination path; a reinforcing material supplying device that supplies reinforcing material to the molding material in the nozzle, the reinforcing material supplying device being configured to supply ... In the reinforcing material supplying device, before the discharging of the shaping material, a reinforced shaping material is generated by cutting and mixing linear reinforcing materials into the flowing shaping material; A method for forming a structure, comprising ejecting the reinforcing material from the nozzle to form the structure.

2. The structure has a portion laminated by at least two adjacent lamination paths, The forming method described in claim 1, characterized in that in the said portion, the lamination path includes a first lamination path that ejects the reinforcing molding material and a second lamination path that ejects a molding material that does not contain the linear reinforcing material.

3. A forming apparatus for forming a layered structure by stacking layers formed of a forming material in a stacking path, comprising: A nozzle that ejects the molding material; a moving device that moves the nozzle according to the lamination path; A forming apparatus comprising: a reinforcing material supplying device that delivers a reinforcing material with a notch to the shaping material in the nozzle.

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