Structure forming method and structure forming system

Abstract

To provide a structure forming method and a structure forming system for efficiently forming a structure by increasing a range of inclination that can be formed by lamination.SOLUTION: A part member is formed by stacking a layer L1 formed by mortar discharged from a nozzle 21 while the nozzle 21 is moved. In this case, a placement surface 16f on which the part member is placed when forming the part member is inclined, and a molding material is piled up on the placement surface 16f such that the thickness of the upper side of the placement surface 16f in the layer formed on the placement surface 16f is thinner than that of the lower side of the placement surface 16f, thereby forming the part member so that the height of the lower side of the part member formed on the placement surface 16f is equal to or greater than the height of the upper side.SELECTED DRAWING: Figure 4

Description

[Technical field]

[0001] The present disclosure relates to a method and system for forming a structure by stacking layers formed from a molding material ejected from a nozzle while moving the nozzle. [Background technology]

[0002] When forming structures such as buildings, three-dimensional (3D) printers are sometimes used. In these 3D printers, layers are formed by discharging material from the nozzle while moving the nozzle. These formed layers are then stacked to form a structure having a three-dimensional shape. Among such structures, a structure having a long side portion on which mortar is laminated and a separator is known (see, for example, Patent Document 1). The structure described in this document has an outer portion having a hole and forming the outer shape of the structure, and an internal structure formed in the hole. The internal structure is made of a member having a higher strength than the outer portion. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2023-69753 A Summary of the Invention [Problem to be solved by the invention]

[0004] As shown in Patent Document 1, when forming an inclined surface by layering mortar, an inclined portion may be provided by shifting the layers of mortar in the inclination direction of the inclined surface. Here, when forming the inclined surface by layering mortar using a 3D printer with the installation surface, which is a horizontal plane, as the starting point, it was only possible to layer the mortar up to the maximum possible angle (for example, 45 degrees). [Means for solving the problem]

[0005] A method for forming a structure that solves the above problem is a method for forming a structure by stacking layers formed with a molding material ejected from a nozzle while moving the nozzle, in which an installation surface on which the structure is placed is inclined when forming the structure, and the molding material is stacked on the installation surface such that the thickness of the layer formed on the installation surface on the upper side of the installation surface is thinner than the thickness of the layer formed on the installation surface on the lower side of the installation surface, thereby forming the structure so that the height of the lower side of the structure formed on the installation surface is greater than or equal to the height of the upper side.

[0006] In addition, a structure formation system that solves the above problem is a structure formation system that includes a control unit that controls the movement of a nozzle, and forms a structure by stacking layers formed with a molding material ejected from the nozzle while moving the nozzle, and includes an installation surface changing mechanism that changes the inclination angle of the installation surface on which the structure is placed when forming the structure so that the top layer formed by ejecting the molding material falls within a stackable inclination angle, and the control unit forms the structure so that the height of the lower side of the structure formed on the installation surface is greater than or equal to the height of the upper side, by changing the inclination angle of the installation surface by driving the installation surface changing mechanism. Effect of the Invention

[0007] According to the present invention, the range of inclination that can be formed by lamination can be increased, so that structures can be formed efficiently. [Brief description of the drawings]

[0008] [Figure 1] FIG. 2 is a top view illustrating the configuration of a structure formed in the first embodiment. [Diagram 2] 2 is a cross-sectional view taken along line 2-2 in FIG. 1. [Diagram 3] FIG. 2 is a front view illustrating the configuration of a base used in the first embodiment. [Figure 4] FIG. 2 is an explanatory diagram illustrating the configuration of a 3D printer and a formation support server that form the structure of the first embodiment. [Diagram 5] FIG. 2 is an explanatory diagram illustrating an example of the hardware configuration in the first embodiment. [Figure 6] FIG. 2 is an enlarged front view illustrating the structure of the first embodiment. [Figure 7] FIG. 11 is an explanatory diagram illustrating the configuration of a 3D printer and a formation support server that form a structure according to a second embodiment. [Figure 8] 11 is an explanatory diagram showing the shape of a structure during its formation in the second embodiment and the posture of the base at that time, in which (a) shows the state immediately after formation of the structure begins, (b) shows the state of the lower part of the structure during its formation, and (c) shows the state after formation of the upper part of the structure has begun. [Figure 9] FIG. 11 is an explanatory diagram illustrating the cross-sectional shape of the structure and the shape of the base in the first modified example, where (a) shows a state in which multiple rod-shaped guide members are provided, and (b) shows a state in which guide members of various shapes are provided. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0009] (First embodiment) A first embodiment of a method and system for forming a structure will be described below with reference to Figs. 1 to 6. In this embodiment, a bench having a ring-shaped upper surface and a cylindrical horizontal cross section is formed as a structure. This bench has an outer shape formed by layering mortar as a molding material using a 3D printer.

[0010] FIG. 1 is a top view of a bench 10 to be formed, and FIG. 2 is a cross-sectional view of the bench 10 in FIG. As shown in the top view of Fig. 1, the bench 10 has a diameter D10 of, for example, about 2 to 4 m. In this embodiment, the bench 10 is formed by joining four parts 11 together with, for example, mortar. Each part 11 is an outer shape part having the same sector shape. In this embodiment, the central angle of this sector shape is 90 degrees.

[0011] As shown in the cross-sectional view of Fig. 2, each part member 11 has a height H2 of, for example, about 0.5 m. The part member 11 has a cross section of a closed loop shape in which a hollow portion 11s is formed. Specifically, the part member 11 is composed of a substantially cylindrical portion 11c that is open downward, and a protruding portion 11p that is connected to the cylindrical portion 11c and has a flat lower surface and protrudes downward. Note that a reinforcing member made of a reinforcing molding material having a higher strength than the part member 11 may be formed in the hollow portion 11s.

[0012] 3, the lower portion 11a of the part member 11 is formed downward (clockwise) at an angle θ1 with respect to the horizontal plane H1. Furthermore, the upper portion 11b of the part member 11 is formed upward (counterclockwise) at an angle θ1 with respect to the horizontal plane H1. The angle θ1 is the maximum angle at which mortar can be layered (45 degrees in this embodiment).

[0013] (Configuration of pedestal 15) 3 is used to form each of the component parts 11. The base 15 includes a main body portion 16 and a protrusion guide portion 17 that protrudes from the main body portion 16.

[0014] The main body 16 has a shape of a triangular prism laid on its side, and has an inclined installation surface 16f that is at an angle θ1 with respect to a horizontal plane H1. The protrusion guide portion 17 is a member that prevents the part member 11 from slipping off during formation. This protrusion guide portion 17 can be inserted into the hollow portion 11s of the part member 11 to be formed, and abuts against the inner wall of the part member 11. For example, when forming a part member 11 having the cross-sectional shape of FIG. 2, this protrusion guide portion 17 may be configured to have a shape having a cross section similar to the shape of the inner peripheral surface. Furthermore, this protrusion guide portion 17 has a height H17. This height H17 is determined according to the number of layers corresponding to the time it takes for the shape of the lowest part to be lost due to hardening of the mortar.

[0015] (Configuration of 3D printer 20 and formation support server 40) Next, the configurations of the 3D printer 20 and the forming support server 40 will be described with reference to Figures 4 and 5. The 3D printer 20 forms each layer constituting the part member 11 in a continuous, unicursal shape.

[0016] (Hardware configuration example) FIG. 5 is a hardware configuration example of an information processing device H10 that functions as the control device 30 of the 3D printer 20 and the formation support server 40 of FIG.

[0017] 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.

[0018] 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 receives input from a designer of a structure or the like.

[0019] The display device H13 is a device that displays various information. The storage device H14 is a storage unit that stores data and various programs for executing various functions of the control device 30 (described later) of the 3D printer 20 and the formation support server 40. Examples of the storage device H14 include a ROM, a RAM, a hard disk, etc.

[0020] The processor H15 uses the programs and data stored in the storage device H14 to control each process in the control device 30 and the formation support server 40. Examples of the processor H15 include a CPU and an MPU.

[0021] (20 features of 3D printer) As shown in FIG. 4, the 3D printer 20 includes a nozzle 21 as a discharge unit, a hose 22, a pressure pump 23, an attachment unit 24, a robot arm 25, and a control device 30.

[0022] The nozzle 21 has a discharge port 21a that opens at its tip. In this embodiment, the discharge port 21a faces downward. An end of a hose 22 is connected to the end of the nozzle 21 opposite to the discharge port 21a. The hose 22 is connected to a pressure pump 23. Mortar supplied to the nozzle 21 through the hose 22 is discharged downward from the discharge port 21a by the pressure of the pressure pump 23.

[0023] A robot arm 25 is attached to the nozzle 21 via an attachment part 24. The nozzle 21 is supported by the robot arm 25 and moves horizontally and vertically in accordance with the movement of the robot arm 25. The movement of the robot arm 25 is controlled by instructions from a nozzle control part 31 of the control device 30. The nozzle control part 31 of this embodiment controls the robot arm 25 so that the direction of mortar discharge from the nozzle 21 is always downward even during movement.

[0024] (Configuration of control device 30) The control device 30 includes a nozzle control unit 31 that executes the structure formation process, and a discharge path storage unit 35. Therefore, by executing the structure formation program stored in the storage unit, the nozzle control unit 31 functions as a stacking management unit 311, a movement control unit 312, and a discharge amount control unit 313.

[0025] The stacking management unit 311 executes a process of managing the path and height of the mortar to be stacked. Specifically, the stacking management unit 311 counts the number of layers that have been piled up, and stores the current number of stacked mortar layers. Then, this stacking management unit 311 stops the movement of the nozzle 21 when the final number of stacked layers of the structure has been formed.

[0026] The movement control unit 312 executes a process for controlling the movement of the robot arm 25 that moves the nozzle 21 according to the path. The discharge amount control unit 313 executes a process of controlling the operation of the pressure pump 23 and controlling the amount of mortar discharged from the nozzle 21.

[0027] The discharge path storage unit 35 records discharge path data of the nozzles 21 that form the part members 11. This discharge path data is recorded when a path is determined by the formation support server 40. The discharge path data includes data related to a structure identifier, a path for each layer identifier, and a discharge amount and speed according to a change point on the path.

[0028] In the structure identifier data area, an identifier for identifying the part member 11 as a structure is recorded. In the layer identifier data area, data regarding the number of layers for each layer forming this structure is recorded.

[0029] The path data area records the movement path of the nozzle 21 of the 3D printer 20 in this layer. This movement path is a path shown in a single stroke from the start point to the end point that constitutes a closed loop in each layer. The path data includes three-dimensional coordinates for specifying the movement path.

[0030] The change point on the route data area records data on the change points (three-dimensional coordinates) on the route where the discharge amount is changed at this level. In the discharge amount data area and the speed data area, data relating to the discharge amount of the nozzle 21 and the speed of the nozzle 21 to be changed at this change point are recorded.

[0031] (Functions of the Formation Support Server 40) Next, the configuration of the formation support server 40 as the formation support system will be described. The formation support server 40 is a computer terminal that determines the movement path of the nozzle 21. The formation support server 40 is connected to the control device 30 of the 3D printer 20, and includes a control unit 41 and a discharge path storage unit 45.

[0032] The control unit 41 functions as a shape specification unit 411 and a path creation unit 412 by executing a path determination program stored in the storage device H14. The shape specifying unit 411 acquires design information of the structure, and specifies the shape of the structure to be formed from the acquired design information. In this embodiment, in response to an instruction from a designer or the like, the shape specifying unit 411 acquires design information of the structure for which a discharge path is to be created from a design information storage unit (not shown).

[0033] The path creation unit 412 creates a path for each layer in a single stroke to form the specified shape of the structure. In this case, it specifies change points on the path and the discharge amount and speed at each change point in response to the thickness (height) of each layer.

[0034] The discharge path data of the generated nozzle 21 is recorded in the discharge path storage unit 45. This discharge path data is recorded when a unicursal path is created by the path creation unit 412. The discharge path data is the same as the discharge path data stored in the discharge path storage unit 35 of the control device 30 of the 3D printer 20, and includes data on the structure identifier, the path for each layer identifier, the discharge amount and speed according to the change point on the path, and the like.

[0035] (Formation support processing) Next, the formation support process in the structure formation support method will be described with reference to FIG. First, the control unit 41 of the forming support server 40 executes a shape specification process. Specifically, the shape specification unit 411 of the control unit 41 specifies the shape of the part component 11 by acquiring design information of the part component 11 to be formed in response to an instruction from a designer.

[0036] Next, the control unit 41 of the formation support server 40 executes a path generation process. Specifically, the path creation unit 412 of the control unit 41 forms a path for the nozzle 21 that discharges mortar for each layer using the identified shape of the part component 11. Furthermore, the path creation unit 412 identifies change points, the discharge amount of the nozzle 21 at each change point, and the speed of the nozzle 21 according to the thickness of the mortar formed in each layer.

[0037] As shown in Fig. 6, in this embodiment, the part member 11 to be formed has a fan shape. In this case, each layer L1 is formed so that it gradually becomes thicker from the thin (low height) inner side L1a on the upper side of the installation surface 16f to the thick (high height) outer side L1b on the lower side of the installation surface 16f. To realize each layer L1, the path creation unit 412 changes the thickness stepwise at an equal rate. Therefore, the path creation unit 412 identifies thickness change points at intervals according to the rate of increase in thickness, and sets the discharge amount and speed of the nozzle 21 to realize this thickness at multiple change points in each layer.

[0038] Then, the path creation unit 412 generates discharge path data for each layer, which associates the movement path in that layer, the change point, and the discharge amount and speed at the change point, and stores the data in the discharge path storage unit 45.

[0039] Thereafter, the control unit 41 of the formation support server 40 transmits the discharge path data stored in the discharge path storage unit 45 to the control device 30 of the 3D printer 20 before forming the structure. The nozzle control unit 31 of the control device 30 stores the acquired discharge path data in the discharge path storage unit 35.

[0040] (Structure formation method) When forming a structure, first, a process of forming the structure that constitutes the part members 11 is executed using the 3D printer 20.

[0041] 4, one layer is formed by discharging mortar from the nozzle 21 of the 3D printer 20 onto the installation surface 16f of the base 15, while moving the nozzle 21 along a path in a single stroke shape. In this case, mortar is discharged from the nozzle 21 around the protrusion guide portion 17 having a shape corresponding to the cross-sectional shape of the part member 11.

[0042] In this formation process, when forming one layer, the nozzle control unit 31 of the 3D printer 20 changes the discharge amount and speed at the change point according to the discharge path data. This forms layers in which the outer side L1b is thicker (higher) than the inner side L1a, as shown in Fig. 6. In this case, the unicursal shape of the path forming each layer is composed of a closed loop in which the start point and end point of each layer are the same.

[0043] Then, when one layer is formed, the nozzle 21 is raised by the height of one layer, and the nozzle 21 is repeatedly moved above the formed layer along the path of that layer. As a result, the mortar is layered. In this case, the bottom layer is formed in a sloping direction along the slope of the installation surface 16f of the base 15, and a new layer is stacked on top of the layer that has been formed. Here, the direction in which the layers are stacked gradually changes from the sloping direction of the installation surface 16f to a vertically upward direction as the layers are stacked. In this case, the height of the outer side L1b of each layer L1 is formed to be the same as the height of the inner side L1a. Then, the top layer of the part member 11 is formed as a layer parallel to the horizontal plane H1 in the horizontal direction, thereby forming the lower part 11a of the part member 11. Note that here, the layer parallel to the horizontal plane H1 is the top layer of the lower part 11a and corresponds to the bottom layer of the upper part 11b.

[0044] Mortar is then continuously layered in the same manner. In this case, layers are stacked vertically on top of layers parallel to the horizontal plane H1. As layers are stacked, they are gradually stacked in a diagonal direction away from the vertical. The stacked layers are then gradually formed approaching the maximum inclination angle at which stacking is possible. Then, the top layer of the part component 11 forms a layer with the maximum inclination angle, forming the upper portion 11b of the part component 11.

[0045] The arrows in Fig. 6 indicate the direction in which the layer directly below the arrow is stacked, which is a direction perpendicular to the direction in which the layer extends. Furthermore, the top layer of the lower portion 11a of the part member 11, which is parallel to the horizontal plane H1 in Fig. 6, also serves as the bottom layer of the upper portion 11b, but the top layer of the lower portion 11a and the bottom layer of the upper portion 11b may be separate layers.

[0046] Through the above steps, a part member 11 is completed that is inclined at an angle θ1 in the vertical direction from the horizontal plane H1. 2 is filled with high-strength mortar, such as mortar containing metal fibers, and then hardened. In this way, the part member 11 is completed.

[0047] (Action of this embodiment) Since the mortar is discharged onto the inclined installation surface 16f of the base 15, the range of inclination that can be layered is expanded in accordance with this inclination.

[0048] According to this embodiment, the following effects can be obtained. (1-1) In this embodiment, the installation surface 16f of the base 15 on which the part components 11 are placed is inclined at an angle θ1 at which mortar can be layered with respect to the horizontal plane H1. This allows mortar to be layered on the inclined installation surface 16f, making it possible to form a continuous part component 11 from a lower angle θ1 to an upper angle θ1 with respect to the horizontal plane H1. This makes it possible to increase the range of inclinations that can be formed, allowing the part components 11 to be formed efficiently.

[0049] (1-2) In this embodiment, the base 15 has a protrusion guide portion 17 that can be inserted into the hollow portion 11s of the part component 11. This makes it possible to prevent mortar from slipping off the installation surface 16f when the part component 11 is formed.

[0050] Second embodiment Next, a second embodiment of the structure forming method and the structure forming system will be described with reference to Figures 7 and 8. In the above embodiment, a base having an inclined installation surface is used, but in this embodiment, a base that inclines according to the stacking is used. In this embodiment, the same components as those in the above embodiment are denoted by the same reference numerals, and detailed description thereof will be omitted.

[0051] As shown in FIG. 7, the 3D printer 50 of this embodiment includes a nozzle 21, a hose 22, a pressure pump 23, an attachment portion 24, a robot arm 25, and a control device 60, similar to the 3D printer 20 of the first embodiment.

[0052] Furthermore, the 3D printer 50 is provided with a tilt mechanism 51 that controls the tilt of the installation surface 55f of the pedestal 55. This tilt mechanism 51 functions as an installation surface changing mechanism, and the pedestal 55 is fixed to its upper surface. The tilt mechanism 51 changes the tilt (tilt angle) of the upper surface (installation surface 55f) of the pedestal 55 in response to an instruction from the control device 60.

[0053] (Configuration of control device 60) The control device 60 includes a nozzle control unit 31 and a discharge path storage unit 35, similar to the control device 30 of the first embodiment.

[0054] Furthermore, the control device 60 includes a base control unit 61 and a base control storage unit 66 . The base control unit 61 controls the tilt of the tilt mechanism 51 of the base 55. In this embodiment, the movement of the tilt mechanism 51 is controlled in accordance with base control data stored in the base control storage unit 66.

[0055] The base control storage unit 66 stores data related to base control for controlling the movement of the tilting mechanism 51. In this embodiment, when forming the lower portion 11a of the part member 11, data for additionally tilting the lower portion 11a in the same direction by a predetermined angle centered on the specified point C1 each time one layer is formed is stored. Here, the predetermined angle is an angle at which a new layer to be formed and stacked is stacked in a horizontal state in a substantially vertical direction. Here, the horizontal state is not limited to a completely horizontal state, but also includes a state in which the effect of gravity acting on the stacked mortar is substantially the same as when it is horizontal, even if the layer is tilted from the horizontal state.

[0056] (Functions of the Formation Support Server 70) Next, a configuration of the formation support server 70 as the formation support system of this embodiment will be described.

[0057] The forming support server 70 is a computer terminal that determines the movement path of the nozzle 21, similar to the forming support server 40 of the first embodiment. This forming support server 70 is connected to the control device 60 of the 3D printer 50. Furthermore, the forming support server 70 includes a control unit 71, a discharge path storage unit 45, and a base control storage unit 76.

[0058] The control unit 71 functions as a shape specification unit 411 and a path creation unit 712 by executing a path determination program stored in the storage device H14. The path creation unit 712 creates a path in each layer in a single stroke to form the shape of the identified structure, similar to the path creation unit 412. Furthermore, the path creation unit 712 also generates base control data in addition to generating the path.

[0059] The generated base control data is recorded in the base control storage unit 76. This base control data is recorded when the path creation unit 712 generates the base control data. The base control data is the same as the base control data stored in the base control storage unit 66 of the control device 60 of the 3D printer 50.

[0060] (Formation support process and structure formation method) In the formation support process in this embodiment, the control unit 71 of the formation support server 70 executes a shape specification process as in the first embodiment. Next, the control unit 71 of the formation support server 70 executes a path generation process. In this case, the path creation unit 712 of the control unit 71 stores discharge path data that forms the path of the nozzle 21 for each layer in the discharge path storage unit 45, similar to the path creation unit 412. Furthermore, the path creation unit 712 generates base control data related to the control of the tilt mechanism 51 when each layer constituting the lower part 11a is formed, along with the generation of the discharge path data. Then, the path creation unit 712 stores the generated base control data in the base control storage unit 76.

[0061] Thereafter, before forming the structure, the control unit 71 of the formation support server 70 transmits the discharge path data stored in the discharge path storage unit 45 and the base control data stored in the base control storage unit 76 to the control device 60 of the 3D printer 50. The control device 60 records the acquired discharge path data and base control data in the discharge path storage unit 35 and the base control storage unit 66, respectively.

[0062] Then, the part member 11 is formed using the 3D printer 50. When forming the part member 11, first, the installation surface 55f of the base 55 is set to be horizontal. Then, one layer is formed by controlling the discharge amount and speed while moving the nozzle 21 along a path that resembles a single stroke according to the movement path data. Then, when one layer is formed and the nozzle 21 rises by one layer, the pedestal control unit 61 controls the tilt mechanism 51 using the pedestal control data. Therefore, the pedestal 55 is tilted by a predetermined angle. As a result, the attitude of the pedestal 55 is changed so that the top surface of the formed top layer becomes approximately horizontal.

[0063] Specifically, as shown in FIG. 8(a), every time one layer is formed, the tilting mechanism 51 is operated to tilt the placement surface 55f by a predetermined angle with the point C1 as the center. Thereafter, one layer is formed by moving the nozzle 21 of the 3D printer 50 along a path that resembles a single stroke while discharging mortar from the nozzle 21 of the 3D printer 50 onto the installation surface 55f of the pedestal 55. Then, when one layer is formed, the nozzle 21 is raised by the height of one layer, and the tilting mechanism 51 is tilted using the pedestal control data to change the tilt angle (posture) of the pedestal 55, and this process is repeated.

[0064] In this case, the inclination of installation surface 55f of base 55 gradually becomes steeper from Figure 8(a) to Figure 8(b) and from Figure 8(b) to Figure 8(c), but the top layer constituting part components 11 is always nearly horizontal, and layers are piled up on this top layer in a nearly vertical direction. As a result, part components 11 on installation surface 55f are stacked with the inside (left side in Figure 8) at the same height as the outside (right side in Figure 8).

[0065] Then, after the lower portion 11a of the part member 11 is formed, layers constituting the upper portion 11b are stacked continuously on the lower portion 11a. In this case, the tilt mechanism 51 may be stopped according to the base control data. Then, the part member 11 is completed, having the lower portion 11a formed as described above and the upper portion 11b formed within the range of angle θ1 from the horizontal plane H1.

[0066] 2 is filled with high-strength mortar and then hardened. In this manner, the part member 11 is completed. According to this embodiment, in addition to the effect similar to that of (1-1) above, the following effect can be obtained.

[0067] (2-1) In this embodiment, the base 55 is tilted each time a layer of mortar constituting the lower portion 11a of the part component 11 is formed, so that the mortar can always be piled up in a vertical direction. Therefore, it is possible to form the part component 11 with a wide range of inclination formed by stacking while suppressing deviation of the position of the soft mortar discharged from the nozzle 21.

[0068] (2-2) In this embodiment, the base control unit 61 of the control device 60 of the 3D printer 50 drives the tilt mechanism 51 to which the base 55 is fixed, using the base control memory unit 66. Therefore, by operating the installation surface 55f of the base 55 using the base control data stored in the base control memory unit 66, each layer of the lower portion 11a of the part member 11 can be formed in a substantially horizontal state.

[0069] 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 first embodiment, the base 15 is provided with the protruding guide portion 17 having a cross section similar to the shape of the hollow portion of the part member 11. The guide member that prevents the mortar that forms the structure from slipping down is not limited to this shape.

[0070] For example, as shown in Fig. 9(a), the part member 81 may be composed of a plurality of spaced apart members that abut against the inside of the part member 81. The part member 81 includes a generally cylindrical portion 81c that is open downward, a protrusion 81p that is connected to the generally cylindrical portion 81c and has a flat lower surface that protrudes downward, and a diamond-shaped support member 81r. The outsides of each corner of the support member 81r abut against the generally cylindrical portion 81c or the protrusion 81p. Then, in a hollow portion 81s of the part member 81, protrusions 83 shaped to abut against the insides of each corner of the support member 81r are provided.

[0071] 9(b), protrusions 87 and guide members 88 of different shapes may be provided to come into contact with the inside of the part member 85. This part member 85 includes a main body 85c having a rounded rectangular shape and a linear support member 85L formed in the approximate center. A plurality of expanding protrusions 87 are provided in a hollow portion 85s above the support member 85L, and a guide member 88 having a shape that matches the support member 85L is provided in a hollow portion 85s below the support member 85L. Furthermore, a guide member 89 that supports the lower side of this part member 85 may be provided on the outside of the part member 85. Furthermore, the base 55 of the second embodiment may be provided with a guide member for preventing the structure to be formed from slipping off the installation surface.

[0072] In the second embodiment, the pedestal control unit 61 drives the tilting mechanism 51 to tilt the pedestal 55 by a predetermined angle each time one layer of mortar constituting the lower portion 11a of the part component 11 is formed. Depending on the shape of the structure to be formed, the pedestal may be tilted at an angle according to the pedestal control data after the formation of multiple layers is completed. Furthermore, instead of controlling the installation surface changing mechanism so that a new layer is stacked at an angle that allows it to be stacked in a nearly vertical direction while being horizontal, as in the second embodiment, the installation surface changing mechanism may be controlled so that the formed top layer falls within an inclination angle that allows stacking.

[0073] Furthermore, in the second embodiment, when forming the upper portion 11b of the part member 11, the tilting mechanism 51 may be driven in the same manner as when forming the lower portion 11a, so that the top layer is always stacked in a substantially horizontal state. In this case, it is preferable to attach a slippage suppression member or the like to a base or the like so that the lower portion 11a of the part member 11 that has already been formed does not fall due to gravity. Here, the projection guide portion 17 of the first embodiment may be used as the slippage suppression member.

[0074] In the above embodiments, the parts members 11, 81, and 85 are formed separately from the protrusion guide portion 17, the protrusions 83 and 87, and the guide members 88 and 89 serving as the guide members. This is not limiting, and a part of the guide member may function as a part of the parts members. Specifically, the guide member is provided so as to be detachable from the base. Then, while stacking mortar around the guide member, the guide member is integrated with the guide member to form a structure. After that, when the formation of the structure is completed by the mortar hardening, the structure is removed from the base together with the guide member.

[0075] In the above embodiments, a fan-shaped part member 11 is formed as a structure. The structure is not limited to a fan shape, and may have an inclination within a range of θ1 upward and downward with respect to a horizontal plane H1. For example, an S-shaped structure may be formed. In this case, the lower part of the structure is connected to the upper part in the shape of a circular arc having a center point different from that of the upper part.

[0076] In addition, a structure having a straight line shape sandwiched between arc shapes, or a structure having a complex connection between arc shapes and straight lines may be formed. In the latter case of forming a complex structure, the member to which the base is fixed may be a member equipped with not only a tilt mechanism but also a linear motion mechanism.

[0077] Next, the technical ideas that can be understood from the above embodiment and other examples will be described below. (a) a method for forming a structure by stacking layers formed of a modeling material discharged from a nozzle while moving the nozzle, the method comprising the steps of: forming a lower portion of the structure by stacking the ejected layers from an oblique direction to a vertical direction; A method for forming a structure, comprising the steps of: ejecting the molding material in succession onto the lower portion to form a layer; stacking the layers in a diagonal direction from the vertical direction to form the upper portion of the structure. (b) a method for assisting in the formation of a structure using a formation system that forms a structure by stacking layers formed with a modeling material, the method comprising: The control unit is generating pedestal control data for controlling an installation surface changing mechanism that changes the inclination angle of an installation surface on which the structure is installed when the structure is formed, so that the top layer formed by discharging the modeling material falls within a stackable inclination angle; A formation support method, comprising: generating a movement path of the nozzle that forms the structure in accordance with the pedestal control data. [Explanation of symbols]

[0078] θ1...angle, C1...point, H1...horizontal surface, H2, H17...height, L1...layer, L1a...inside, L1b...outside, D10...diameter, 10...bench, 11, 81, 85...parts, 11a...lower part, 11b...upper part, 11c, 81c...cylindrical part, 11p, 81p, 83, 87...projection part, 11s, 81s, 85s...hollow part, 15, 55...base, 16, 85c...main body, 16f, 55f...installation surface, 17...projection guide part, 20, 50...3D printer, 21...nozzle, 21a...discharge port, 22...hose, 23 ...pressure pump, 24...mounting unit, 25...robot arm, 30,60...control device, 31...nozzle control unit, 35...discharge path memory unit, 40,70...forming support server, 41,71...control unit, 45...discharge path memory unit, 51...tilt mechanism as installation surface changing mechanism, 61...base control unit, 66,76...base control memory unit, 81r...support member, 85L...support unit, 88,89...guide member, 311...stacking management unit, 312...movement control unit, 313...discharge amount control unit, 411...shape identification unit, 412,712...path creation unit.

Claims

1. A method for forming a structure by stacking layers formed of a modeling material discharged from a nozzle while moving the nozzle, comprising the steps of: When forming the structure, an installation surface on which the structure is installed is inclined; A method for forming a structure, comprising stacking the molding material on the installation surface in a layer formed on the installation surface such that the thickness of the upper side of the installation surface is thinner than the thickness of the lower side of the installation surface, thereby forming the structure so that the height of the lower side of the structure formed on the installation surface is greater than or equal to the height of the upper side.

2. The method for forming a structure according to claim 1 , wherein the inclination angle of the installation surface is changed so that the uppermost layer formed by ejecting the molding material falls within a range of inclination angles at which stacking is possible.

3. A guide member is provided on the installation surface in accordance with the shape of the structure, The method for forming a structure according to claim 1 or 2, wherein the structure is formed by discharging the shaping material so that the shaping material abuts against the guide member.

4. A structure forming system including a control unit for controlling movement of a nozzle, the system forming a structure by stacking layers formed of a modeling material discharged from the nozzle while moving the nozzle, the system comprising: an installation surface changing mechanism that changes an inclination angle of an installation surface on which the structure is installed when the structure is formed, so that a top layer formed by discharging the shaping material falls within a stackable inclination angle; The control unit is A structure formation system characterized by stacking the molding material on the installation surface while changing the inclination angle of the installation surface by driving the installation surface changing mechanism, so that the thickness of the upper side of the installation surface in the layer formed on the installation surface is thinner than the lower side of the installation surface, thereby forming the structure so that the height of the lower side of the structure formed on the installation surface is greater than or equal to the height of the upper side.

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