Molding device

Abstract

To mold a high precision molding, by reducing influence of strain of a table due to weight of a molding material.SOLUTION: A discharge head 30 discharges the molding material. A moving mechanism 40 changes the relative position between the table and the discharge head 30. A discharge control unit 11 controls the discharge of the molding material by the discharge head 30 based on molding data used to form the object. A movement control unit 12 controls the moving mechanism 40 based on the molding data. A correction amount determination unit 13 determines a correction amount of the relative vertical position between the table and the discharge head 30 according to the table's distortion based on the amount of molding material discharged onto the table by the discharge head 30. The movement control unit 12 corrects the relative position based on the correction amount determined by the correction amount determination unit 13.SELECTED DRAWING: Figure 5

Description

[Technical Field]

[0001] The present disclosure relates to a modeling apparatus. [Background technology]

[0002] Currently, there are known modeling devices that build objects by stacking a modeling material dispensed from a dispensing head onto a table. In such modeling devices, as the load on the table increases with the progress of stacking the modeling material, the table becomes distorted. As a result, the relative vertical position between the modeling material on the table and the dispensing head may shift, potentially preventing the creation of a highly accurate model. Therefore, there is a need for technology that reduces the impact of the weight of the modeling material.

[0003] Patent Document 1 describes a technology for reducing the effect of deflection due to the weight of the laminate in a three-dimensional printer that forms a laminate by stacking ejected materials. Specifically, Patent Document 1 describes a technology for maintaining the table horizontal by offsetting deflection of a holding means that holds the table due to the weight of the laminate with rocking by a rocking means. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Patent Application Laid-Open No. 2018-69590 Summary of the Invention [Problem to be solved by the invention]

[0005] However, the technology described in Patent Document 1 is a technology for reducing the effects of bending of the holding means that holds the table, but is not a technology for reducing the effects of distortion of the table. Therefore, it is difficult to apply the technology described in Patent Document 1 to a modeling device in which distortion occurs in the table due to the weight of the modeling material. For this reason, there is a demand for a technology that reduces the effects of distortion of the table due to the weight of the modeling material and enables the modeling of a highly accurate model.

[0006] The present disclosure has been made in consideration of the above-mentioned problems, and aims to provide a molding apparatus that reduces the influence of distortion of a table due to the weight of a molding material and molds a highly accurate object. [Means for solving the problem]

[0007] In order to achieve the above object, a molding apparatus according to the present disclosure includes: A modeling apparatus that forms a model by stacking modeling materials, a table on which the build material is deposited; and a discharge head that discharges the modeling material; a moving mechanism for changing the relative position between the table and the ejection head; a discharge control unit that controls the discharge of the modeling material from the discharge head based on modeling data for forming the model; a movement control unit that controls the movement mechanism based on the modeling data; and a correction amount determination unit that determines a correction amount of a relative position between the table and the discharge head in a vertical direction according to a distortion of the table, based on a discharge amount of the modeling material discharged onto the table by the discharge head; The movement control unit corrects the relative position based on the correction amount determined by the correction amount determination unit.

[0008] The amount of downward displacement of the portion of the table corresponding to the position of the dispensing head depends on the magnitude of the load on the table. Therefore, with the above configuration, the influence of table distortion due to the weight of the modeling material can be reduced, and a model can be manufactured with high precision.

[0009] a discharge amount estimation unit that estimates a target discharge amount, which is a discharge amount of the modeling material to be discharged into a correction target area that corresponds to the position of the discharge head among a plurality of individual areas that constitute the entire area of ​​the table, The correction amount determination unit may determine the correction amount based on the target discharge amount estimated by the discharge amount estimation unit.

[0010] The amount of downward displacement of the portion of the table corresponding to the correction target area is largely dependent on the magnitude of the load acting on the correction target area of ​​the table. Therefore, with the above configuration, it is possible to appropriately reduce the influence of distortion of the table 92 due to the weight of the modeling material.

[0011] The correction amount determination unit may determine the correction amount based on the target ejection amount and the position of the correction target region.

[0012] The downward displacement of the portion of the table 92 corresponding to the correction target area depends not only on the target discharge rate but also on the position of the correction target area. Therefore, with the above configuration, it is possible to further appropriately reduce the influence of distortion of the table 92 due to the weight of the modeling material.

[0013] the discharge amount estimating unit, when the correction target area is an object placement area among the plurality of individual areas in which the object is placed, and an adjacent area adjacent to the correction target area is not the object placement area, estimates an adjacent discharge amount, which is a discharge amount of the modeling material to be discharged into the adjacent area; The correction amount determination unit may determine the correction amount based on the target ejection amount and the adjacent ejection amount.

[0014] If the adjacent area adjacent to the correction target area is not an object placement area, the weight of the modeling material dispensed into this adjacent area is applied to the portion of the table corresponding to the correction target area. Therefore, with the above configuration, it is possible to further appropriately reduce the influence of the weight of the modeling material on the table distortion.

[0015] a discharge amount estimating unit that estimates an individual discharge amount, which is a discharge amount of the modeling material discharged into each of a plurality of individual areas that constitute the entire area of ​​the table; The correction amount determination unit may determine the correction amount based on the individual discharge amount estimated by the discharge amount estimation unit.

[0016] The amount of downward displacement of the portion of the table corresponding to the correction target area depends not only on the load acting on the correction target area of ​​the table but also on the loads acting on other individual areas of the table. Therefore, with the above configuration, it is possible to appropriately reduce the influence of the weight of the modeling material on the table distortion.

[0017] The correction amount determination unit may determine the correction amount based on the individual ejection amount for each of the plurality of individual areas, the position in the entire area of ​​the table, and the positional relationship with the correction target area among the plurality of individual areas that corresponds to the position of the ejection head.

[0018] The amount of downward displacement of the portion of the table corresponding to the area to be corrected depends not only on the load applied to each individual area but also on the position of each individual area and the positional relationship between each individual area and the area to be corrected. Therefore, with the above configuration, it is possible to further appropriately reduce the influence of the weight of the modeling material on the table.

[0019] a discharge amount estimation unit that estimates a total discharge amount, which is a discharge amount of the modeling material discharged onto the entire area of ​​the table; The correction amount determination unit may determine the correction amount based on the total ejection amount estimated by the ejection amount estimation unit.

[0020] The amount of downward displacement of the portion of the table corresponding to the dispensing head depends on the load applied to the entire area of ​​the table. Therefore, with the above configuration, it is possible to easily reduce the influence of distortion of the table due to the weight of the modeling material.

[0021] The correction amount determination unit may determine the correction amount based on the total ejection amount and the position of the ejection head.

[0022] The amount of downward displacement of the portion of the table corresponding to the dispensing head depends on the load applied to the entire area of ​​the table and the position of the dispensing head. Therefore, with the above configuration, the influence of the weight of the modeling material on the table can be easily and appropriately reduced.

[0023] a discharge amount estimation unit that estimates a discharge amount of the modeling material discharged onto the table by the discharge head during modeling of the model, The correction amount determination unit may determine the correction amount based on the discharge amount estimated by the discharge amount estimation unit during modeling of the object.

[0024] According to the above configuration, it is not necessary to determine the correction amount beforehand before forming the object, and it is considered that the estimation accuracy of the amount of the modeling material to be dispensed is high.

[0025] a discharge amount estimating unit that estimates a discharge amount of the modeling material to be discharged onto the table by the discharge head based on the modeling data before modeling the model, The correction amount determination unit may determine the correction amount based on the discharge amount estimated by the discharge amount estimation unit before the object is formed.

[0026] According to the above configuration, the processing load during the formation of the object is reduced. [Effects of the Invention]

[0027] According to the present disclosure, the influence of distortion of the table due to the weight of the modeling material can be reduced, and a model can be manufactured with high accuracy. [Brief explanation of the drawings]

[0028] [Figure 1] 1 is an external view of a modeling apparatus according to a first embodiment; [Figure 2] FIG. 1 is an external view of a head moving mechanism according to a first embodiment; [Figure 3] FIG. 1 is an external view of a table moving mechanism according to the first embodiment; [Figure 4] 1 is an external view of a modeling table according to the first embodiment; [Figure 5] 1 is a diagram illustrating a configuration of a molding apparatus according to a first embodiment. [Figure 6]1A and 1B are diagrams showing the state of distortion of the printing table due to the load, where (A) is a side view of the printing table before printing starts, and (B) is a side view of the printing table during printing. [Figure 7] A diagram showing the magnitude of the effect on each individual area due to the load on that area. [Figure 8] An explanatory diagram illustrating that the weight of the modeling material dispensed into the adjacent area is applied to the correction target area. [Figure 9] 1 is a flowchart showing a modeling process executed by the modeling apparatus according to the first embodiment; [Figure 10] Flowchart showing the correction amount determination process shown in FIG. 9 [Figure 11] A diagram showing the magnitude of the effect of the load on each individual area on the area to be corrected. [Figure 12] 10 is a flowchart showing a correction amount determination process according to the second embodiment. [Figure 13] FIG. 10 is an explanatory diagram of a correction amount determination method according to the third embodiment. [Figure 14] Flowchart showing correction amount determination processing according to the fourth embodiment DETAILED DESCRIPTION OF THE INVENTION

[0029] (Embodiment 1) The appearance of a modeling apparatus 100 according to this embodiment will be described with reference to FIG. 1. FIG. 1 is a perspective view of the modeling apparatus 100. The modeling apparatus 100 is an apparatus that models an object by layering a modeling material. The modeling apparatus 100 is also called a 3D printer. In this embodiment, the modeling apparatus 100 models an object by fused deposition modeling. The fused deposition modeling is a method of creating a three-dimensional shape by melting a thermoplastic resin at a high temperature and layering the melted resin. In this embodiment, the modeling apparatus 100 uses resin pellets as the modeling material.

[0030] As shown in FIG. 1, the modeling apparatus 100 includes a discharge head 30, a discharge head 30A, a first head moving mechanism 60, a second head moving mechanism 70, a table moving mechanism 80, and a table 92. As shown in FIG. 4, the table 92 is provided on a modeling table 90. In this embodiment, the modeling apparatus 100 models a model without using the discharge head 30A out of the discharge head 30 and the modeling table 90. Hereinafter, the mechanisms for moving the discharge head 30 and the modeling table 90 will be mainly described, and a description of the mechanism for moving the discharge head 30A will be omitted. Furthermore, descriptions of members, housings, etc. for fixing each mechanism will be omitted as appropriate.

[0031] In this embodiment, the Z axis is an axis that extends in the vertical direction, the X axis is an axis that is perpendicular to the Z axis, and the Y axis is an axis that is perpendicular to the X and Z axes. The direction in which the X axis arrow extends is the positive X axis direction, and the opposite direction to the X axis arrow is the negative X axis direction. The direction in which the Y axis arrow extends is the positive Y axis direction, and the opposite direction to the Y axis arrow is the negative Y axis direction. The direction in which the Z axis arrow extends is the positive Z axis direction, and the opposite direction to the Z axis arrow is the negative Z axis direction. Hereinafter, the positive X axis direction will be referred to as the right, the negative X axis direction as the left, the positive Y axis direction as the front, the negative Y axis direction as the back, the positive Z axis direction as the up, and the negative Z axis direction as the down, as appropriate.

[0032] The head moving mechanism 50 included in the modeling apparatus 100 will be described with reference to Fig. 2. Fig. 2 is a perspective view of the head moving mechanism 50. The head moving mechanism 50 is a mechanism for moving the discharge head 30. In this embodiment, the head moving mechanism 50 is a mechanism for moving the discharge head 30 in the horizontal direction. The head moving mechanism 50 includes a first head moving mechanism 60 and a second head moving mechanism 70.

[0033] The first head moving mechanism 60 is a mechanism for moving the ejection head 30 in the left-right direction, which is the X-axis direction. The first head moving mechanism 60 includes a first head moving mechanism 60A and a first head moving mechanism 60B. The first head moving mechanism 60A is a mechanism for moving one end of the second head moving mechanism 70 in the left-right direction. The first head moving mechanism 60B is a mechanism for moving the other end of the second head moving mechanism 70 in the left-right direction.

[0034] The first head moving mechanism 60A includes a pulley 61A, a pulley 62A, a belt 63A, a guide rail 64A, a guide block 65A, and a motor (not shown). The pulleys 61A and 62A are disk-shaped components used for power transmission together with the belt 63A. The belt 63A is a belt for moving the ejection head 30. The belt 63A is stretched over the pulleys 61A and 62A. The guide rail 64A guides the guide block 65A in the left-right direction. The guide rail 64A extends in the left-right direction.

[0035] The guide block 65A is fixed to one end of the second head moving mechanism 70 and guides the one end of the second head moving mechanism 70 in the left-right direction. In addition, the guide block 65A or one end of the second head moving mechanism 70 is fixed to a part of the belt 63A. A motor (not shown) rotates the pulley 61A and the pulley 62A. When the motor (not shown) is driven, the pulley 61A and the pulley 62A rotate, causing the belt 63A to move, and one end of the second head moving mechanism 70 moves in the left-right direction while being guided by the guide rail 64A.

[0036] The first head moving mechanism 60B basically has the same configuration as the first head moving mechanism 60A. The first head moving mechanism 60B includes a pulley 61B, another pulley (not shown), a belt 63B, a guide rail 64B, a guide block 65B, and a motor (not shown). When the motor (not shown) is driven, the pulley 61B and the other pulley (not shown) rotate, moving the belt 63B, and the other end of the second head moving mechanism 70 is guided by the guide rail 64B and moves left and right. At this time, the ejection head 30, which is fixed to the second head moving mechanism 70 so as to be movable in the front and rear directions, moves left and right together with the second head moving mechanism 70.

[0037] The second head movement mechanism 70 is a mechanism for moving the ejection head 30 in the front-to-rear direction, which is the Y-axis direction. The second head movement mechanism 70 includes a frame 71, two pulleys (not shown), a belt 73, a guide rail 74A, a guide rail 74B, a guide block 75, and a motor (not shown). The frame 71 is a member extending in the front-to-rear direction. The two pulleys (not shown) are provided on both ends of the frame 71. The belt 73 is stretched over the two pulleys (not shown).

[0038] Guide rails 74A and 74B guide guide block 75 in the front-to-rear direction. Guide block 75 is fixed to discharge head 30 and guides discharge head 30 in the front-to-rear direction. Guide block 75 or discharge head 30 is fixed to a part of belt 73. When a motor (not shown) is driven, two pulleys (not shown) rotate, causing belt 73 to move, and discharge head 30 moves in the front-to-rear direction while being guided by guide rails 74A and 74B.

[0039] Next, with reference to FIG. 3, the table moving mechanism 80 provided in the modeling apparatus 100 will be described. FIG. 3 is a perspective view of the table moving mechanism 80. The table moving mechanism 80 is a mechanism for moving a modeling table 90 provided with a table 92. Moving the modeling table 90 corresponds to moving the table 92. In this embodiment, the table moving mechanism 80 is a mechanism for moving the table 92 in the vertical direction. The table moving mechanism 80 includes a table moving mechanism 80A and a table moving mechanism 80B. The table moving mechanism 80A is a mechanism for moving one end of the modeling table 90 in the vertical direction. The table moving mechanism 80B is a mechanism for moving the other end of the modeling table 90 in the vertical direction.

[0040] The table movement mechanism 80A includes a support plate 81A, a lead screw 82A, a motor 83A, a guide rail 85A, and a guide block 86A. The support plate 81A is a plate that supports one end of the modeling table 90 and is fixed to one end of the modeling table 90. The lead screw 82A is a mechanical element that converts rotational motion into linear motion. The lead screw 82A is rotatably held by the support plate 81A. The motor 83A is a motor that rotates the lead screw 82A.

[0041] The guide rail 85A guides the guide block 86A in the vertical direction. The guide rail 85A extends in the vertical direction. The guide block 86A is fixed to one end of the modeling table 90 and guides the one end of the modeling table 90 in the vertical direction. When the motor 83A is driven to rotate the lead screw 82A, the one end of the modeling table 90 fixed to the support plate 81A moves in the vertical direction while being guided by the guide rail 85A.

[0042] The table movement mechanism 80B basically has the same configuration as the table movement mechanism 80A. That is, the table movement mechanism 80B includes a support plate 81B, a lead screw 82B, a motor (not shown), a guide rail 85B, and a guide block (not shown). When the motor (not shown) is driven to rotate the lead screw 82B, the other end of the modeling table 90 fixed to the support plate 81B is guided by the guide rail 85B and moves up and down.

[0043] Next, the modeling table 90 provided in the modeling apparatus 100 will be described with reference to Fig. 4. Fig. 4 is a perspective view of the modeling table 90. The modeling table 90 is a table on which a modeled object is placed. The modeling table 90 includes a base 91 and a table 92. The base 91 is a base that serves as the foundation for the table 92. The base 91 is formed, for example, of a rectangular frame. The base 91 includes a protruding plate 93A at one end in the left-right direction, which is the longitudinal direction, and a protruding plate 93B at the other end.

[0044] Protruding plate 93A and protruding plate 93B are plates that protrude outward. Protruding plate 93A is attached to support plate 81A included in table movement mechanism 80A. Protruding plate 93A has a recess 94A through which lead screw 82A is passed and a through hole 95A through which guide rail 85A is passed. Protruding plate 93B is attached to support plate 81B included in table movement mechanism 80B. Protruding plate 93B has a recess 94B through which lead screw 82B is passed and a through hole 95B through which guide rail 85B is passed.

[0045] The table 92 is a plate-like member on which a model is placed. The table 92 is placed on and fixed to a base 91. The table 92 is positioned by positioning pins (not shown) attached within the frame of the base 91, and is fixed onto the base 91. The modeling table 90 moves up and down by a table moving mechanism 80.

[0046] Next, the function of each unit included in the modeling apparatus 100 will be described with reference to Fig. 5. The modeling apparatus 100 includes a control unit 10, a storage unit 21, a display unit 22, an operation reception unit 23, a communication unit 24, a discharge head 30, and a movement mechanism 40.

[0047] The control unit 10 controls the overall operation of the modeling apparatus 100. The control unit 10 includes a CPU (Central Processing Unit), ROM (Read Only Memory), RAM (Random Access Memory), RTC (Real Time Clock), etc. The CPU is also called a central processing unit, central arithmetic unit, processor, microprocessor, microcomputer, DSP (Digital Signal Processor), etc., and functions as a central processing unit that executes processing and calculations related to the control of the modeling apparatus 100. In the control unit 10, the CPU reads programs and data stored in the ROM and uses the RAM as a work area to perform overall control of the modeling apparatus 100. The RTC is, for example, an integrated circuit with a timekeeping function. The CPU can determine the current date and time from time information read from the RTC.

[0048] The storage unit 21 includes a nonvolatile semiconductor memory such as a flash memory, an EPROM (Erasable Programmable ROM), or an EEPROM (Electrically Erasable Programmable ROM), and serves as a so-called secondary storage device or auxiliary storage device. The storage unit 21 stores programs and data used by the control unit 10 to execute various processes. The storage unit 21 also stores data generated or acquired by the control unit 10 as a result of executing various processes.

[0049] The display unit 22 displays various images under the control of the control unit 10. The display unit 22 includes a touch screen, a liquid crystal display, etc. The operation reception unit 23 receives various operations from the user and supplies information indicating the contents of the received operations to the control unit 10. The operation reception unit 23 includes a touch screen, a button, a lever, etc.

[0050] The communication unit 24 communicates with various devices (not shown) in accordance with various wireless communication standards or various wired communication standards under the control of the control unit 10. Examples of various wireless communication standards include Wi-Fi (registered trademark), LTE (Long Term Evolution), 4G (4th Generation), 5G (5th Generation), Bluetooth (registered trademark), Zigbee (registered trademark), etc. Examples of various wired communication standards include USB (Universal Serial Bus, registered trademark), Thunderbolt (registered trademark), etc. The communication unit 24 includes a communication interface that complies with various communication standards.

[0051] The discharge head 30, under the control of the control unit 10, discharges the modeling material supplied from a tank (not shown) toward the table 92 or an object being modeled on the table 92. The modeling material discharged by the discharge head 30 is adjusted to an appropriate temperature and viscosity by a heating mechanism (not shown).

[0052] The movement mechanism 40 is a mechanism that changes the relative position between the table 92 and the discharge head 30. This change in relative position is achieved by changing the position of at least one of the table 92 and the discharge head 30. For example, a change in the relative position in the left-right direction, the front-back direction, or the up-down direction is achieved by changing the position of at least one of the table 92 and the discharge head 30 in each of the left-right direction, the front-back direction, and the up-down direction.

[0053] In this embodiment, a change in the relative position in the left-right direction is achieved by changing the position of the ejection head 30 in the left-right direction. A change in the relative position in the front-rear direction is achieved by changing the position of the ejection head 30 in the front-rear direction. A change in the relative position in the up-down direction is achieved by changing the position of the table 92 in the up-down direction.

[0054] The movement mechanism 40 includes a head movement mechanism 50 and a table movement mechanism 80. The head movement mechanism 50 includes a first head movement mechanism 60 and a second head movement mechanism 70. The first head movement mechanism 60 moves the discharge head 30 in the left-right direction to change the relative position between the table 92 and the discharge head 30 in the left-right direction. The second head movement mechanism 70 moves the discharge head 30 in the front-rear direction to change the relative position between the table 92 and the discharge head 30 in the front-rear direction. The table movement mechanism 80 moves the table 92 in the up-down direction to change the relative position between the table 92 and the discharge head 30 in the up-down direction.

[0055] Next, the main functions of the control unit 10 will be described in detail. Functionally, the control unit 10 includes a discharge control unit 11, a movement control unit 12, a correction amount determination unit 13, and a discharge amount estimation unit 14. Each of these functions is realized by software, firmware, or a combination of software and firmware. The software and firmware are written as programs and stored in the ROM or storage unit 21. The CPU then executes the programs stored in the ROM or storage unit 21 to realize each of these functions.

[0056] The discharge control unit 11 controls the discharge of the modeling material by the discharge head 30 based on modeling data for forming a modeled object. The discharge control unit 11 controls the discharge of the modeling material by the discharge head 30 in cooperation with the movement control unit 12. In other words, the discharge control unit 11 causes the discharge head 30 to discharge the modeling material when the relative position of the table 92 and the discharge head 30 is at a position where the modeling material should be discharged.

[0057] The modeling data is, for example, slice data. The slice data is data obtained by dividing a 3D model of a model into layers. In other words, the slice data is data that specifies the locations in each layer where the modeling material should be ejected. The slice data includes at least one of raster data and vector data.

[0058] Raster data is data made up of cells arranged in a grid of rows and columns. In other words, raster data is data in which a value is assigned to each cell, like bitmap data. Raster control, which is discharge control using raster data, makes it possible to discharge modeling material for each cell. Therefore, raster control allows for precise discharge. Raster control is an image control that uses coordinates to draw dots in units of dots.

[0059] Vector data is data that expresses the coordinates of points or lines connecting points as numerical data. Vector data is, for example, data that represents the trajectory of the modeling material discharged by the discharge head 30. Vector control, which is discharge control using vector data, enables continuous discharge of the modeling material. Therefore, vector control is expected to increase the modeling speed. Vector control is control of the image of drawing a line.

[0060] The discharge control unit 11 controls the amount of modeling material discharged by the discharge head 30. For example, the discharge control unit 11 controls the amount of discharge so that the pass width and layer pitch are constant. In this case, the amount of discharge is roughly the product of the pass width, layer pitch, discharge length, and specific gravity. The pass width is the width of the discharged modeling material when viewed from the top and bottom. The layer pitch is the thickness of one layer of the discharged modeling material, and is the length in the top and bottom direction of the discharged modeling material. The discharge length is the length of the discharged modeling material when viewed from the top and bottom. The specific gravity is the specific gravity of the modeling material. The discharge control unit 11 may also control the amount of discharge per unit time so that it is constant.

[0061] The movement control unit 12 controls the movement mechanism 40 based on the modeling data. The movement control unit 12, in cooperation with the discharge control unit 11, moves the discharge head 30 and the table 92 so that the multiple layers that make up the modeled object are formed one by one, starting from the lowest layer. For example, the movement control unit 12 controls the table moving mechanism 80 to move the table 92 to a reference position for the lowest layer. The reference position for the lowest layer is basically a vertical position suitable for forming the lowest layer. Then, the movement control unit 12 controls the first head moving mechanism 60 and the second head moving mechanism 70 to move the discharge head 30 in the left-right and front-back directions so that the modeling material can be discharged to a position in the lowest layer where the modeling material should be discharged.

[0062] After the bottom layer is formed, the movement control unit 12 controls the table movement mechanism 80 to move the table 92 to the reference position for the next layer. That is, the movement control unit 12 moves the table 92 downward by the distance of one layer. The reference position for the next layer is basically a vertical position suitable for forming the next layer. Hereinafter, the vertical reference position suitable for forming each layer will be referred to as the reference position for each layer, as appropriate. The movement control unit 12 controls the first head movement mechanism 60 and the second head movement mechanism 70 to move the discharge head 30 left and right and front and back so that the modeling material can be discharged to the position where the modeling material should be discharged in this layer.

[0063] The movement control unit 12 repeats the above-described movement control until the top layer is formed and the model is completed. The reference position for each layer is the position on the table 92 where the difference in elevation from the tip of the discharge head 30 to the landing point of the modeling material is a reference value. If this difference in elevation deviates from the reference value, deviations will occur in the path width of the modeling material, the layer pitch of the modeling material, the landing point of the modeling material, etc., resulting in a decrease in the accuracy of the modeled object. When forming the bottom layer, the landing point of the modeling material is the part on the table 92 that overlaps with the tip of the discharge head 30 when viewed from the top. When forming layers other than the bottom layer, the landing point of the modeling material is the top of the layered modeling material that overlaps with the tip of the discharge head 30 when viewed from the top.

[0064] The correction amount determination unit 13 determines a correction amount corresponding to the distortion of the table 92, based on the amount of modeling material discharged onto the table 92 by the discharge head 30. This correction amount is a correction amount for the relative position in the vertical direction between the table 92 and the discharge head 30. As the modeling progresses, the weight of the in-progress model, which is the model in the middle of being formed on the table 92, increases, and the load on the table 92 also increases.

[0065] In this case, even if both ends of the table 92 are positioned at the reference positions of each layer, the position of the portion of the table 92 on which the in-progress model is placed will be lower than the reference position. As a result, the difference in height from the tip of the dispensing head 30 to the landing point of the modeling material will be greater than the reference value. Therefore, the correction amount determination unit 13 determines the correction amount for the relative positions of the table 92 and the dispensing head 30 in the vertical direction so that this difference in height approaches the reference value. This correction amount corresponds to the increase in the difference in height due to the increase in the weight of the in-progress model.

[0066] The movement control unit 12 corrects the relative positions in the vertical direction between the table 92 and the discharge head 30, based on the correction amount determined by the correction amount determination unit 13. In other words, the movement control unit 12 raises the table 92 by an amount corresponding to an increase in height difference that corresponds to an increase in the weight of the intermediately formed object.

[0067] A method for correcting the position of the table 92 will be described below with reference to FIG. 6. FIG. 6(A) is a side view of the modeling table 90 before modeling begins. FIG. 6(B) is a side view of the modeling table 90 during modeling. Below, an example will be described in which the modeling table 90 is fixed to the table moving mechanism 80 at fixed points P1 and P2, and modeling material is discharged to a discharge target point P3, as shown in FIG. 4. In this embodiment, the positions of the fixed points P1, P2, and P3 in the Y-axis direction are the center positions of the modeling table 90 in the Y-axis direction. Furthermore, the discharge point P4 is the tip of the discharge head 30. Note that, because the discharge target point P3 and the discharge point P4 overlap when viewed from the top-bottom direction, the X- and Y-coordinates of the discharge target point P3 and the discharge point P4 are the same.

[0068] 6(A), before modeling begins, the modeling table 90 is hardly distorted, and therefore the Z coordinates of fixed point P1, fixed point P2, and discharge target point P3 are the same. In this embodiment, the X coordinate of fixed point P1 is x1, the X coordinate of fixed point P2 is x2, the X coordinate of discharge target point P3 and discharge point P4 is x3, the Z coordinate of fixed point P1, fixed point P2, and discharge target point P3 is y1, and the Z coordinate of discharge point P4 is y2. Note that z2 - z1 = Δz1. Also, x3 - x1 = x2 - x3 = L10.

[0069] 6(B), during the modeling of the intermediate object 200, the modeling table 90 is moved downward by the thickness of the intermediate object 200 so that the distance from the discharge target point P5 to the discharge point P4 on the intermediate object 200 is maintained at Δz1. When the thickness of the intermediate object 200 is Δz2, the Z coordinates of the fixed points P1 and P2 are z1 - Δz2 = z3. However, when the discharge target point P3 is far from the fixed points P1 and P2, the modeling table 90 is affected by a load corresponding to the weight of the intermediate object 200.

[0070] As a result, the modeling table 90 distorts downward, and the Z coordinate of the discharge target point P3 is z3 - Δz3 = z4. Δz3 is the distance that the discharge target point P3 has descended due to the distortion of the modeling table 90. As a result, the Z coordinate of the discharge target point P5 is z1 - Δz3 = z5. Therefore, due to the distortion of the modeling table 90, the distance from the discharge target point P5 to the discharge point P4 is Δz1 + Δz3 = Δz4, and not Δz1. In this case, proper modeling will not be performed, and there is a high possibility that the accuracy of the modeled object will decrease.

[0071] Therefore, it is preferable to correct the position of the modeling table 90 in the Z-axis direction so that the distance from the discharge target point P5 to the discharge point P4 is maintained at Δz1. Specifically, it is preferable to raise the modeling table 90 by Δz3. In other words, it is preferable to determine the amount of correction for the vertical position of the table 92 as Δz3. When the discharge target point P5 is raised to the discharge target point P6 through correction, the distance from the discharge target point P6 to the discharge point P4 becomes Δz4-Δz3=Δz1, which is Δz1.

[0072] Here, the method for calculating the correction amount can be adjusted as appropriate. In this embodiment, the correction amount determination unit 13 determines the correction amount based on the target discharge amount estimated by the discharge amount estimation unit 14. The target discharge amount is the amount of modeling material discharged into the correction target area. In this embodiment, the discharge amount is expressed in terms of mass rather than volume. The correction target area is an area that corresponds to the position of the discharge head 30 among multiple individual areas that make up the entire area of ​​the table 92, and is the area that is subject to correction.

[0073] The method by which the discharge amount estimation unit 14 estimates the target discharge amount can be adjusted as appropriate. For example, when the path width and layer pitch of the modeling material discharged from the discharge head 30 are constant, the target discharge amount may be estimated from the path width, layer pitch, discharge length, and specific gravity. For example, the discharge amount estimation unit 14 may calculate the discharge length of the modeling material discharged to the correction target region for each layer constituting the in-progress model 200, and calculate the target discharge amount as the product of the sum of the discharge lengths of each layer, the path width, the layer pitch, and the specific gravity. Note that this target discharge amount is an estimated value when the cross-sectional shape of the elongated discharged modeling material is considered to be a rectangle with long sides having a length corresponding to the path width and short sides having a length corresponding to the layer pitch.

[0074] Alternatively, when the amount of the modeling material discharged from the discharge head 30 per unit time is constant, the target discharge amount may be estimated based on the discharge time of the modeling material. For example, the discharge amount estimation unit 14 may obtain the discharge time during which the modeling material is discharged onto the correction target region for each layer constituting the in-progress model 200, and calculate the target discharge amount as the product of the sum of the discharge times of each layer and the discharge amount per unit time.

[0075] The method by which the correction amount determination unit 13 determines the correction amount from the target discharge amount can be adjusted as appropriate. For example, the correction amount determination unit 13 can determine the correction amount based on the target discharge amount and the position of the correction target area.

[0076] FIG. 7 is a diagram showing the magnitude of the effect of a load on each individual region. In this embodiment, region E0, which is the entire region of table 92, is divided into four in the X-axis direction and the Y-axis direction, and region E0 is divided into 4 x 4 = 16 individual regions. Region E0, which is the entire region, includes the following individual regions: region E1, region E2, region E3, region E4, region E5, region E6, region E7, region E8, region E9, region E10, region E11, region E12, region E13, region E14, region E15, and region E16. The region to be corrected is one of these 16 individual regions that overlaps with the ejection head 30 when viewed from above and below. Note that the 16 individual regions have the same shape and area.

[0077] Here, the farther an individual region is from fixed points P1 and P2, the more susceptible it is to the load based on the weight of the in-progress object 200, and the greater the downward displacement. In other words, even if the in-progress object 200 of the same weight is placed on the correction target region, the farther the correction target region is from fixed points P1 and P2, the greater the downward distortion of the portion of the table 92 corresponding to the correction target region. Note that being far from fixed points P1 and P2 corresponds to being far from both fixed points P1 and P2. In other words, being far from fixed points P1 and P2 corresponds to being far from the nearest fixed point, which is the closest fixed point between fixed points P1 and P2.

[0078] 7 shows that the darker the shaded area, the farther it is from fixed points P1 and P2 and the more susceptible it is to the effects of the load. Specifically, FIG. 7 shows that areas E2, E3, E14, and E15 are most susceptible to the effects of the load, areas E1, E4, E6, E7, E10, E11, E13, and E16 are somewhat susceptible to the effects of the load, and areas E5, E8, E9, and E12 are least susceptible to the effects of the load.

[0079] Therefore, the correction amount determination unit 13 determines the correction amount so that the larger the target discharge amount is and the farther the correction target area is from the fixed point P1 and the fixed point P2, the larger the correction amount. For example, the correction amount determination unit 13 can calculate the correction amount from the target discharge amount using a calculation formula prepared in advance for each individual area. An example of the calculation formula is assumed to be D1 = W1 × k1. Note that D1 is the downward displacement of the portion of the table 92 corresponding to the individual area due to the weight of the item placed in the individual area. W1 is the weight of the item placed in the individual area. k1 is a proportionality constant according to the position of the individual area and is prepared for each individual area.

[0080] k1 can be determined, for example, by an experiment or simulation in which the downward displacement of a portion of table 92 corresponding to an individual area is measured with articles of various weights placed in the individual area. The correction amount determination unit 13 can determine the correction amount by calculating D1=W1×k1, where D1 is the correction amount, W1 is the target discharge amount, and k1 is a proportionality constant corresponding to the area to be corrected. Instead of using the above-mentioned formula for determining the correction amount from the target discharge amount, the correction amount determination unit 13 may determine the correction amount using a table showing the correspondence between the target discharge amount and the correction amount. Information indicating these calculation formulas or these tables is stored, for example, in the storage unit 21.

[0081] Incidentally, some objects have an overhanging shape, in which an upper layer protrudes outward more than a lower layer. In such objects, the load of the building material dispensed into a certain individual area may be applied not to that individual area on the table 92, but to an adjacent individual area on the table 92. In this case, it is preferable to correct the position of the table 92 with respect to the individual area on the table 92 that is subject to the load, rather than to the individual area on the table 92 that is not subject to the load.

[0082] Below, with reference to Fig. 8, the loads acting on each individual region on the table 92 when a mortar-shaped object is being formed will be described. Dashed line 201 indicates the outer edge of the bottom surface of the mortar-shaped object. Dashed line 202 indicates the outer edge of the top surface of the mortar-shaped object. Fig. 8 shows an example in which the forming material is dispensed into regions E6, E7, E10, and E11 in the bottom layer, and in which the forming material is dispensed into regions E2, E3, E14, and E15 in the top layer in addition to regions E6, E7, E10, and E11.

[0083] In this case, it is considered that a load is applied to the individual regions on the bottom layer of the table 92 into which the modeling material has been dispensed, and that no load is applied to the individual regions on the bottom layer of the table 92 into which the modeling material has not been dispensed. Specifically, it is considered that a load is applied to regions E6, E7, E10, and E11 on the table 92, and that no load is applied to regions E2, E3, E14, and E15 on the table 92. It is also considered that the load of the modeling material dispensed into regions E2, E3, E14, and E15 is applied to regions E6, E7, E10, and E11 on the table 92.

[0084] For example, the load of the modeling material dispensed into region E2 is considered to be applied to region E6 adjacent to region E2 on the table 92. That is, in addition to the load of the modeling material dispensed into region E6, the load of the modeling material dispensed into region E2 adjacent to region E6 is also considered to be applied to region E6 on the table 92. Similarly, in addition to the load of the modeling material dispensed into region E7, the load of the modeling material dispensed into region E3 adjacent to region E7 is also considered to be applied to region E7 on the table 92.

[0085] Therefore, it is preferable to determine the correction amount for the correction target region by taking into consideration whether each individual region is a model-placement region. An object-placement region is an individual region among all the individual regions where a model is placed, and is an individual region into which the modeling material is dispensed at the bottom. In the example shown in Fig. 8, the object-placement regions are four regions: region E6, region E7, region E10, and region E11.

[0086] Therefore, when the correction target area is an object placement area and the adjacent area adjacent to the correction target area is not an object placement area, the discharge amount estimation unit 14 estimates the adjacent discharge amount, which is the amount of modeling material to be discharged into the adjacent area.The correction amount determination unit 13 then determines the correction amount based on the target discharge amount and the adjacent discharge amount.For example, the correction amount determination unit 13 can determine the correction amount by calculating D1 = (W1 + W12) × k1, where D1 is the correction amount, W1 is the target discharge amount, W12 is the adjacent discharge amount, and k1 is a proportionality constant corresponding to the correction target area.

[0087] Next, a description will be given of a formation process executed by the formation apparatus 100 with reference to a flowchart shown in Fig. 9. The formation process is executed in response to the formation apparatus 100 receiving an instruction to start the formation process from a user, for example.

[0088] First, the control unit 10 included in the modeling apparatus 100 acquires modeling data (Step S101). For example, the control unit 10 acquires modeling data from the storage unit 21 or another device. After completing the process of Step S101, the control unit 10 moves the table 92 to the reference position of the lowest layer (Step S102). For example, the control unit 10 controls the table moving mechanism 80 so that the vertical positions of the fixed points P1 and P2 on the modeling table 90 become the reference positions of the lowest layer.

[0089] When the control unit 10 completes the process of step S102, it starts the modeling process for one layer (step S103). The modeling process for one layer is a process of modeling one of the multiple layers that make up the modeled object, for example, by controlling the head moving mechanism 50 and the table moving mechanism 80 based on slice data for one layer.

[0090] When the control unit 10 completes the process of step S103, it determines whether the correction target area has been changed (step S104). A change in the correction target area corresponds to a change in the individual areas where the ejection heads 30 overlap when viewed from the top-bottom direction. When the control unit 10 determines that the correction target area has been changed (step S104: YES), it corrects the position of the table 92 by the amount of correction according to the correction target area (step S105).

[0091] For example, the control unit 10 controls the table moving mechanism 80 so that the vertical positions of the fixed points P1 and P2 on the modeling table 90 are raised by the correction amount corresponding to the correction target area relative to the reference positions of the layer being generated. The correction amount corresponding to the correction target area is determined in the correction amount determination process in step S108, which will be described later, when the modeling process of the previous layer is completed. In the modeling process of the bottom layer, the correction amount corresponding to the correction target area is 0.

[0092] When the control unit 10 determines that the correction target region has not been changed (step S104: NO) or when the process of step S105 is completed, the control unit 10 determines whether or not the modeling process for one layer has been completed (step S106). When the control unit 10 determines that the modeling process for one layer has not been completed (step S106: NO), the control unit 10 returns the process to step S104. On the other hand, when the control unit 10 determines that the modeling process for one layer has been completed (step S106: YES), the control unit 10 determines whether or not the modeled object has been completed (step S107). That is, the control unit 10 determines whether or not there is any layer that has not yet been modeled.

[0093] When the control unit 10 determines that the modeling object is complete (step S107: YES), it completes the modeling process. On the other hand, when the control unit 10 determines that the modeling object is not complete (step S107: NO), it executes a correction amount determination process (step S108). The correction amount determination process will be described below with reference to the flowchart shown in FIG. 10. The correction amount determination process is a process for determining a correction amount corresponding to each individual region.

[0094] First, the control unit 10 selects an individual region (step S201). For example, the control unit 10 selects an unselected individual region from the 16 individual regions. After completing the process of step S201, the control unit 10 determines whether the selected individual region is a modeling object placement region (step S202). For example, the control unit 10 determines whether a modeling material has been applied to the selected individual region in the bottom layer. If the control unit 10 determines that the selected individual region is not a modeling object placement region (step S202: NO), it sets the correction amount for the selected individual region to 0 (step S203).

[0095] When the control unit 10 determines that the selected individual area is a model placement area (step S202: YES), it estimates the amount of modeling material dispensed into the selected individual area (step S204). That is, the control unit 10 estimates the amount of modeling material dispensed into the selected individual area from the start of modeling of the object to the present.

[0096] After completing the process of step S204, the control unit 10 determines whether there is an adjacent area that is not an object placement area (step S205). More specifically, the control unit 10 determines whether there is an adjacent area that is not an object placement area among the areas adjacent to the selected individual area. If the control unit 10 determines that there is no adjacent area that is not an object placement area (step S205: NO), the control unit 10 determines the correction amount for the selected individual area from the discharge amount for the selected individual area (step S206). For example, the control unit 10 calculates the correction amount for the selected individual area from the discharge amount for the selected individual area based on a formula or table associated with the selected individual area.

[0097] When the control unit 10 determines that there is an adjacent region that is not an object placement region (step S205: YES), it estimates the dispensed amount of the building material dispensed to the adjacent region that is not an object placement region (step S207). That is, the control unit 10 estimates the dispensed amount of the building material dispensed to the adjacent region that is not an object placement region from the start of building the object to the present. After completing the process of step S207, the control unit 10 determines the correction amount for the selected individual region from the dispensed amount for the selected individual region and the dispensed amount for the adjacent region that is not an object placement region (step S208). For example, the control unit 10 calculates the correction amount for the selected individual region from the dispensed amount for the selected individual region and the dispensed amount for the adjacent region that is not an object placement region, based on a formula or a table associated with the selected individual region.

[0098] When the control unit 10 completes the processing of step S203, step S206, or step S208, it determines whether or not there are any unselected individual areas (step S209). If the control unit 10 determines that there are any unselected individual areas (step S209: YES), it returns the processing to step S201. If the control unit 10 determines that there are no unselected individual areas (step S209: NO), it completes the correction amount determination processing.

[0099] When the control unit 10 completes the correction amount determination process of step S108, it moves the table 92 to the reference position of the next layer (step S109). For example, the control unit 10 controls the table moving mechanism 80 so that the positions of the fixed points P1 and P2 on the modeling table 90 in the vertical direction are lowered by one layer. When the control unit 10 completes the process of step S109, it corrects the position of the table 92 by the correction amount according to the correction target region (step S110).

[0100] For example, the control unit 10 controls the table moving mechanism 80 so that the vertical positions of the fixed points P1 and P2 on the modeling table 90 are raised by an amount corresponding to the correction target area relative to the reference positions of the layer to be generated. After completing the process of step S110, the control unit 10 returns the process to step S103.

[0101] In this embodiment, the relative position between the table 92 and the discharging head 30 is corrected based on a correction amount determined based on the amount of modeling material dispensed. Here, the amount of downward displacement of the portion of the table 92 corresponding to the position of the discharging head 30 depends on the magnitude of the load applied to the table 92. Therefore, according to this embodiment, the influence of distortion of the table 92 due to the weight of the modeling material can be reduced, and a modeled object with high accuracy can be formed.

[0102] Furthermore, in this embodiment, the correction amount is determined based on the amount of modeling material ejected onto the correction target area corresponding to the position of the ejection head 30. Here, the amount of downward displacement of the portion of the table 92 corresponding to the correction target area depends greatly on the magnitude of the load applied to the correction target area on the table 92. Therefore, according to this embodiment, it is possible to appropriately reduce the influence of distortion of the table 92 due to the weight of the modeling material.

[0103] In this embodiment, the correction amount is determined based on the target discharge amount and the position of the correction target area. Here, the downward displacement amount of the portion of the table 92 corresponding to the correction target area depends not only on the target discharge amount but also on the position of the correction target area. Therefore, according to this embodiment, the influence of distortion of the table 92 due to the weight of the modeling material can be further appropriately reduced.

[0104] Furthermore, in this embodiment, when the correction target region is a modeling object placement region and the adjacent region adjacent to the correction target region is not a modeling object placement region, the correction amount is determined based on the target discharge amount and the adjacent discharge amount. Here, when the adjacent region adjacent to the correction target region is not a modeling object placement region, the weight of the modeling material dispensed to this adjacent region is applied to the portion of the table 92 that corresponds to the correction target region. Therefore, according to this embodiment, it is possible to further appropriately reduce the influence of the distortion of the table 92 due to the weight of the modeling material.

[0105] In the present embodiment, the discharge amount estimation unit 14 estimates the amount of the modeling material discharged by the discharge head 30 onto the table 92 during the modeling of the object, and the correction amount determination unit 13 determines the correction amount during the modeling of the object, based on the discharge amount estimated by the discharge amount estimation unit 14. Therefore, according to the present embodiment, it is not necessary to determine the correction amount in advance before the modeling of the object, and it is considered that the estimation accuracy of the discharge amount of the modeling material is high.

[0106] (Embodiment 2) In the first embodiment, an example was described in which the amount of modeling material ejected onto individual areas other than the area to be corrected is not generally taken into consideration when determining the correction amount. In the present embodiment, an example is described in which the amount of modeling material ejected onto individual areas other than the area to be corrected is taken into consideration when determining the correction amount. Hereinafter, descriptions of the same configurations, functions, etc. as those in the first embodiment will be omitted or simplified.

[0107] As described in the first embodiment, the amount of downward displacement of the portion of table 92 corresponding to the area to be corrected depends greatly on the load applied to the area to be corrected on table 92. However, the amount of downward displacement of the portion of table 92 corresponding to the area to be corrected also depends on the load applied to other individual areas on table 92. Therefore, in this embodiment, an example will be described in which the load applied to each of all individual areas on table 92 is taken into consideration when determining the amount of correction.

[0108] In this embodiment, the discharge amount estimation unit 14 estimates individual discharge amounts, which are the amounts of the modeling material discharged into each of the multiple individual areas that make up the entire area of ​​the table 92. In other words, the discharge amount estimation unit 14 estimates the amount of the modeling material discharged for each individual area. The correction amount determination unit 15 determines the correction amount based on the individual discharge amounts estimated by the discharge amount estimation unit 14. In other words, the correction amount determination unit 15 determines the correction amount by taking into account not only the amount of the modeling material discharged into the correction target area but also the amount of the modeling material discharged into other individual areas.

[0109] More specifically, the correction amount determination unit 15 determines the correction amount based on the individual discharge rate of each of the multiple individual areas, its position in the entire area of ​​the table 92, and its positional relationship with the area to be corrected. Here, the amount of downward displacement of the portion of the table 92 corresponding to the area to be corrected depends on the load applied to each individual area on the table 92, but the degree of dependence differs depending on the position of each individual area, the positional relationship between each individual area and the area to be corrected, etc.

[0110] For example, the amount of downward displacement depends greatly on the load applied to individual areas distant from fixed point P1 and fixed point P2, but does not depend very much on the load applied to individual areas close to fixed point P1 or fixed point P2. Also, for example, the amount of downward displacement depends greatly on the load applied to the area to be corrected, but does not depend very much on the load applied to other individual areas distant from the area to be corrected.

[0111] Therefore, the correction amount determination unit 15 determines the correction amount based not only on the individual ejection amount of each individual area but also on the position of each individual area and the positional relationship between each individual area and the area to be corrected. Hereinafter, with reference to Fig. 11, it will be explained that the downward displacement amount depends on the positional relationship between each individual area and the area to be corrected. It should be noted that the dependence of the downward displacement amount on the position of each individual area has already been explained with reference to Fig. 7.

[0112] Fig. 11 is a diagram showing the magnitude of the effect of the load on each individual region on the correction target region. In the example shown in Fig. 11, the correction target region is region E6. The closer an individual region is to the correction target region, the greater the effect it has on the correction target region. In other words, even if the same weight of the in-progress model 200 is placed on each individual region, the closer this individual region is to the correction target region, the greater the downward distortion of the portion of the table 92 corresponding to the correction target region.

[0113] 11 shows that the darker the shaded area, the closer the individual area is to the correction target area and the greater the influence it has on the correction target area. Specifically, FIG. 11 shows that area E6 has the greatest influence on the correction target area, areas E1, E2, E3, E5, E7, E9, E10, and E11, which are adjacent to area E6, have a medium influence on the correction target area, and areas E4, E8, E12, E13, E14, E15, and E16, which are not adjacent to area E6, have the smallest influence on the correction target area.

[0114] Therefore, the correction amount determination unit 13 determines the correction amount so that the correction amount increases as the ejection rate increases, as the individual area is farther from the fixed points P1 and P2, and as the individual area is closer to the area to be corrected. For example, the correction amount determination unit 13 can determine the correction amount by adding together a first correction amount for suppressing the influence of the load applied to the area to be corrected and the sum of second correction amounts for suppressing the influence of the loads applied to other individual areas.

[0115] The first correction amount corresponds to the correction amount described in embodiment 1. That is, the first correction amount can be determined by calculating D1=W1×k1, where D1 is the first correction amount, W1 is the target ejection amount, and k1 is a proportional constant corresponding to the correction target area.

[0116] The second correction amount can be calculated from the amount of ink discharged into each individual area, the position of each individual area, and the positional relationship between each individual area and the correction target area using a calculation formula or table prepared in advance for each combination of individual areas. An example of the calculation formula is D2 = W2 × k2. D2 is the downward displacement of the portion of the table 92 corresponding to the correction target area due to the weight of an item placed in the other individual area. W2 is the weight of the item placed in the other individual area. k2 is a proportionality constant corresponding to the position of the other individual area and the positional relationship between the other individual area and the correction target area, and is prepared for each other individual area and for each positional relationship between the other individual area and the correction target area. k2 increases as the distance from the other individual area to the nearest fixed point increases and as the other individual area is closer to the correction target area.

[0117] k2 can be determined, for example, by an experiment or simulation that measures the downward displacement of a portion of table 92 corresponding to the correction target area when items of various weights are placed in the other individual areas. The correction amount determination unit 13 can determine the second correction amount by calculating D2 = W2 × k2, where D2 is the second correction amount, W2 is the amount of ejection into the other individual area, and k2 is a proportionality constant that corresponds to the position of the other individual area and the positional relationship between the other individual area and the correction target area. The correction amount determination unit 13 may determine the second correction amount using a table corresponding to the above calculation formula instead of the above calculation formula. Information indicating these calculation formulas or these tables is stored, for example, in the storage unit 21.

[0118] The correction amount determination process according to this embodiment will be described below with reference to the flowchart shown in FIG.

[0119] First, the control unit 10 selects an individual area (step S301). After completing the process of step S301, the control unit 10 estimates the ejection amount in the selected individual area (step S302). After completing the process of step S302, the control unit 10 determines a first correction amount in the selected individual area (step S303). For example, the control unit 10 calculates the first correction amount in the selected individual area from the ejection amount in the selected individual area based on a formula or table for calculating the first correction amount.

[0120] When the control unit 10 completes the process of step S303, it determines whether or not there are any unselected individual areas (step S304). If the control unit 10 determines that there are any unselected individual areas (step S304: YES), it returns the process to step S301. If the control unit 10 determines that there are no unselected individual areas (step S304: NO), it selects an individual area (step S305).

[0121] Upon completing the process of step S305, the control unit 10 determines the second correction amount for the selected individual area (step S306). For example, the control unit 10 calculates the second correction amount for the selected individual area from the ejection amounts for the other individual areas and the positional relationship between the selected individual area and the other individual areas, based on a calculation formula or table for calculating the second correction amount. The control unit 10 calculates the second correction amount for all other individual areas as the second correction amount for the selected individual area.

[0122] After completing the process of step S306, the control unit 10 determines the correction amount for the selected individual region (step S307). For example, the control unit 10 determines the sum of the first correction amount for the selected individual region and the sum of all second correction amounts for the selected individual region as the correction amount for the selected individual region.

[0123] When the control unit 10 completes the process of step S307, it determines whether or not there are any unselected individual areas (step S308). If the control unit 10 determines that there are any unselected individual areas (step S308: YES), it returns the process to step S305. If the control unit 10 determines that there are no unselected individual areas (step S308: NO), it completes the correction amount determination process.

[0124] In this embodiment, the correction amount is determined based on the amount of modeling material dispensed into each of the multiple individual regions that make up the entire region of the table 92. Here, the downward displacement amount of the portion of the table 92 that corresponds to the region to be corrected depends not only on the load applied to the region to be corrected on the table 92, but also on the loads applied to the other individual regions on the table 92. Therefore, according to this embodiment, it is possible to appropriately reduce the influence of distortion of the table 92 due to the weight of the modeling material.

[0125] Furthermore, in this embodiment, the correction amount is determined based on the individual discharge amount of each of the multiple individual regions, its position in the entire area of ​​the table 92, and its positional relationship with the correction target region. Here, the downward displacement amount of the portion of the table 92 corresponding to the correction target region depends not only on the load applied to each individual region, but also on the position of each individual region and the positional relationship between each individual region and the correction target region. Therefore, according to this embodiment, the influence of distortion of the table 92 due to the weight of the modeling material can be further appropriately reduced.

[0126] (Embodiment 3) In the first embodiment, an example in which the correction amount is determined based on the amount of the modeling material dispensed into the correction target area has been described, while in the second embodiment, an example in which the correction amount is determined based on the amount of the modeling material dispensed into each of all individual areas has been described. In the present embodiment, an example in which the correction amount is determined based on the amount of the modeling material dispensed into all areas of the table 92 will be described. Hereinafter, the description of the same configurations, functions, etc. as those in the first and second embodiments will be omitted or simplified.

[0127] In this embodiment, the discharge amount estimation unit 14 estimates the total discharge amount, which is the amount of modeling material discharged onto the entire area of ​​the table 92. Then, the correction amount determination unit 13 determines the correction amount based on the total discharge amount estimated by the discharge amount estimation unit 14. More specifically, the correction amount determination unit 13 determines the correction amount based on the total discharge amount and the position of the discharge head 30. The correction amount determination unit 13 increases the correction amount as the total discharge amount increases and as the position of the discharge head 30 is farther from the fixed point P1 and the fixed point P2.

[0128] 13, a method for the correction amount determination unit 13 to determine the correction amount based on the total discharge amount and the position of the discharge head 30 will be described below. Discharge target point P7 is a point on the table 92 that overlaps with the discharge head 30 when viewed from the top and bottom. The distance from fixed point P1 to discharge target point P7 is L1, and the distance from fixed point P2 to discharge target point P7 is L2. Since L2 is shorter than L1, the closest fixed point is fixed point P2.

[0129] The correction amount determination unit 13 can calculate the correction amount from the total discharge amount using a calculation formula prepared in advance for each distance from the nearest fixed point. An example of the calculation formula is assumed to be D3 = W3 × k3. Note that D3 is the downward displacement of a portion of the table 92 corresponding to the position of the discharge head 30 due to the weight of the item placed on the table 92. W3 is the weight of the item placed on the table 92. k3 is a proportionality constant according to the distance from the nearest fixed point, and is a proportionality constant prepared for each distance from the nearest fixed point. Information indicating these calculation formulas or these tables is stored, for example, in the memory unit 21.

[0130] k3 can be found, for example, by an experiment or simulation that measures the amount of downward displacement of each part of the table 92 with articles of various weights placed on the table 92. The correction amount determination unit 13 can find the correction amount by calculating D3 = W3 × k3, where D3 is the correction amount, W3 is the total discharge amount, and k3 is a proportionality constant according to L2.

[0131] In this embodiment, the correction amount is determined based on the total discharge amount, which is the amount of modeling material discharged onto the entire area of ​​the table 92. Here, the amount of downward displacement of the portion of the table 92 corresponding to the discharge head 30 depends on the load applied to the entire area of ​​the table 92. According to this embodiment, the influence of distortion of the table 92 due to the weight of the modeling material can be easily reduced.

[0132] Furthermore, in this embodiment, the correction amount is determined based on the total discharge amount and the position of the discharge head 30. Here, the amount of downward displacement of the portion of the table 92 corresponding to the discharge head 30 depends not only on the load applied to the entire area of ​​the table 92 but also on the position of the discharge head 30. According to this embodiment, the influence of distortion of the table 92 due to the weight of the modeling material can be easily and appropriately reduced.

[0133] (Fourth embodiment) In the first embodiment, an example was described in which the amount of the modeling material dispensed into each individual region is estimated during modeling of the object, and the correction amount for the correction target region is determined. In the present embodiment, an example is described in which the amount of the modeling material dispensed into each individual region is estimated before modeling of the object, and the correction amount for the correction target region is determined. Hereinafter, descriptions of the same configurations, functions, etc. as those in the first to third embodiments will be omitted or simplified.

[0134] In this embodiment, the discharge amount estimation unit 14 estimates the amount of the modeling material to be discharged by the discharge head 30 onto the table 92 based on the modeling data before the modeling of the object. Also, in this embodiment, the correction amount determination unit 13 determines the correction amount based on the discharge amount estimated by the discharge amount estimation unit 14 before the modeling of the object.

[0135] The correction amount determination process according to this embodiment will be described below with reference to the flowchart shown in Fig. 14. In this embodiment, the correction amount determination process is executed before the formation of a model.

[0136] First, the control unit 10 identifies a configuration object placement area from the slice data of the lowest layer (step S401). That is, the control unit 10 identifies an individual area in the lowest layer into which the configuration material is to be discharged as the configuration object placement area. Note that it is assumed that, prior to the correction amount determination process, configuration data including slice data of each layer has been generated from a 3D model of the configuration object.

[0137] After completing the process of step S401, the control unit 10 determines the correction amounts for the individual areas that are not object placement areas and the bottom layer to be 0 (step S402). That is, the control unit 10 determines the correction amounts for all layers for the individual areas that are not object placement areas to be 0. Furthermore, the control unit 10 determines the correction amounts for all individual areas for the bottom layer to be 0. After completing the process of step S402, the control unit 10 selects the next higher layer (step S403). It is assumed that the bottom layer is selected at the start of the correction amount determination process.

[0138] After completing the process of step S403, the control unit 10 selects an individual area that is a modeling object placement area (step S404). After completing the process of step S404, the control unit 10 estimates the amount of modeling material to be dispensed into the selected individual area (step S405). That is, the control unit 10 estimates the amount of modeling material to be dispensed into the selected individual area in the layer below the currently selected layer.

[0139] After completing the process of step S405, the control unit 10 determines whether there is an adjacent region that is not a structure placement region (step S406). If the control unit 10 determines that there is no adjacent region that is not a structure placement region (step S406: NO), the control unit 10 determines the correction amount for the selected individual region from the discharge amount for the selected individual region (step S407).

[0140] When the control unit 10 determines that there is an adjacent region that is not a structure placement region (step S406: YES), it estimates the amount of the formation material dispensed in the adjacent region that is not a structure placement region (step S408). That is, the control unit 10 estimates the amount of the formation material dispensed to the adjacent region that is not a structure placement region in the layer below the selected layer. After completing the process of step S408, the control unit 10 determines the correction amount for the selected individual region from the amount of the formation material dispensed in the selected individual region and the amount of the formation material dispensed in the adjacent region that is not a structure placement region (step S409).

[0141] Upon completing the processing of step S407 or step S409, the control unit 10 determines whether or not there is an unselected individual area that is an object placement area (step S410). If the control unit 10 determines that there is an unselected individual area that is an object placement area (step S410: YES), the control unit 10 returns the processing to step S404. If the control unit 10 determines that there is no unselected individual area that is an object placement area (step S411: NO), the control unit 10 determines whether or not the selected layer is the top layer (step S412). If the control unit 10 determines that the selected layer is not the top layer (step S412: NO), the control unit 10 returns the processing to step S403. If the control unit 10 determines that the selected layer is the top layer (step S412: YES), the control unit 10 completes the correction amount determination processing.

[0142] In this embodiment, before the object is formed, the amount of the modeling material to be discharged onto the table 92 is estimated, and the correction amount is determined based on the estimated amount of the modeling material. Therefore, according to this embodiment, the processing load during the formation of the object is reduced.

[0143] (Variation) Although the embodiments have been described above, modifications and applications in various forms are possible. It is up to the discretion of the individual to adopt any of the configurations, functions, and operations described in the above embodiments. Furthermore, in addition to the above-described configurations, functions, and operations, additional configurations, functions, and operations may be adopted. Furthermore, the configurations, functions, and operations described in the above embodiments can be freely combined.

[0144] In the first embodiment, an example has been described in which the movement mechanism 40 includes a head movement mechanism 50 that moves the discharge head 30 in the horizontal direction and a table movement mechanism 80 that moves the table 92 in the vertical direction. The movement mechanism 40 may have any configuration as long as it is a mechanism that can change the relative positional relationship between the discharge head 30 and the table 92. For example, the movement mechanism 40 may include a head movement mechanism that moves the discharge head 30 in the vertical direction and a table movement mechanism that moves the table 92 in the horizontal direction. Alternatively, for example, the movement mechanism 40 may include a head movement mechanism that moves the discharge head 30 in the horizontal and vertical directions and a table movement mechanism that moves the table 92 in the horizontal and vertical directions.

[0145] In the first to third embodiments, an example has been described in which the correction amount for the relative position between the dispensing head 30 and the table 92 is determined based on the amount of modeling material dispensed onto the table 92. The method for determining the correction amount is not limited to this example. For example, the distance from a reference plane may be measured for each individual area of ​​the table 92, and the correction amount may be determined based on the measured distance. The reference plane may be, for example, the floor on which the modeling apparatus 100 is installed or the bottom surface of the modeling apparatus 100. In this case, distance measuring sensors may be disposed at positions corresponding to each individual area on the reference plane, and each distance measuring sensor may measure the distance from the reference plane to each individual area of ​​the table 92. The shorter the measured distance, the longer the correction amount is set. The distance measuring sensor may be a laser sensor that measures the time between emitting laser light and receiving reflected light of the laser light.

[0146] In the embodiment, the CPU of the control unit 10 executes a program stored in the ROM or the storage unit 21 to function as each unit shown in FIG. 5 . However, in the present disclosure, the control unit 10 may be dedicated hardware. Dedicated hardware may be, for example, a single circuit, a composite circuit, a programmed processor, an ASIC (Application Specific Integrated Circuit), an FPGA (Field-Programmable Gate Array), or a combination thereof. When the control unit 10 is dedicated hardware, the functions of each unit may be realized by individual hardware, or the functions of each unit may be realized collectively by a single piece of hardware. Furthermore, some of the functions of each unit may be realized by dedicated hardware, and other functions may be realized by software or firmware. In this way, the control unit 10 can realize each of the above-described functions by hardware, software, firmware, or a combination thereof.

[0147] The present disclosure allows various embodiments and modifications without departing from the broad spirit and scope of the present disclosure. Furthermore, the above-described embodiments are intended to explain the present disclosure and do not limit the scope of the present disclosure. That is, the scope of the present disclosure is defined by the claims, not the embodiments. Various modifications made within the scope of the claims and the meaning of equivalent disclosures are considered to be within the scope of the present disclosure. [Explanation of symbols]

[0148] E0,E1,E2,E3,E4,E5,E6,E7,E8,E9,E10,E11,E12,E13,E14,E15,E16 area P1,P2 fixed point P3, P5, P6, P7 Discharge target points P4 discharge point 10 Control Unit 11 Discharge control section 12 Movement control unit 13 Correction amount determination unit 14 Discharge amount estimator 21 Memory section 22 Display section 23 Operation reception section 24 Communications Department 30,30A Discharge Head 40 Moving mechanism 50 Head movement mechanism 60, 60A, 60B First head moving mechanism 61A, 61B, 62A, 62B pulleys 63A, 63B, 73 Belt 64A, 64B, 74A, 74B, 85A, 85B guide rails 65A, 65B, 75A, 75B, 86A guide block 70 Second head movement mechanism 71 frames 80, 80A, 80B Table movement mechanism 81A,81B Support plate 82A, 82B lead screw 83A motor 90 Modeling stand 91 Foundation 92 tables 93A,93B Projecting plate 94A, 94B recess 95A,95B through hole 100 Modeling equipment 200 Part-time model 201,202 dashed line

Claims

1. A modeling apparatus that forms a model by stacking modeling materials, a table on which the build material is deposited; and a discharge head that discharges the modeling material; a moving mechanism for changing the relative position between the table and the ejection head; a discharge control unit that controls the discharge of the modeling material from the discharge head based on modeling data for forming the model; a movement control unit that controls the movement mechanism based on the modeling data; and a correction amount determination unit that determines a correction amount of a relative position between the table and the discharge head in a vertical direction according to a distortion of the table, based on a discharge amount of the modeling material discharged onto the table by the discharge head; the movement control unit corrects the relative position based on the correction amount determined by the correction amount determination unit. Modeling equipment.

2. a discharge amount estimation unit that estimates a target discharge amount, which is a discharge amount of the modeling material to be discharged into a correction target area that corresponds to the position of the discharge head among a plurality of individual areas that constitute the entire area of ​​the table, the correction amount determination unit determines the correction amount based on the target discharge amount estimated by the discharge amount estimation unit. The molding apparatus according to claim 1 .

3. the correction amount determination unit determines the correction amount based on the target ejection amount and the position of the correction target region. The molding apparatus according to claim 2 .

4. the discharge amount estimating unit, when the correction target area is an object placement area among the plurality of individual areas in which the object is placed, and an adjacent area adjacent to the correction target area is not the object placement area, estimates an adjacent discharge amount, which is a discharge amount of the modeling material to be discharged into the adjacent area; the correction amount determination unit determines the correction amount based on the target ejection amount and the adjacent ejection amount. The molding apparatus according to claim 2 or 3.

5. a discharge amount estimating unit that estimates an individual discharge amount, which is a discharge amount of the modeling material discharged into each of a plurality of individual areas that constitute the entire area of ​​the table; the correction amount determination unit determines the correction amount based on the individual discharge amounts estimated by the discharge amount estimation unit. The molding apparatus according to claim 1 .

6. the correction amount determination unit determines the correction amount based on the individual ejection amount for each of the plurality of individual regions, a position in the entire region of the table, and a positional relationship with a correction target region among the plurality of individual regions that corresponds to the position of the ejection head; The molding apparatus according to claim 5 .

7. a discharge amount estimation unit that estimates a total discharge amount, which is a discharge amount of the modeling material discharged onto the entire area of ​​the table; the correction amount determination unit determines the correction amount based on the total ejection amount estimated by the ejection amount estimation unit. The molding apparatus according to claim 1 .

8. the correction amount determination unit determines the correction amount based on the total ejection amount and the position of the ejection head. The molding apparatus according to claim 7 .

9. a discharge amount estimation unit that estimates a discharge amount of the modeling material discharged onto the table by the discharge head during modeling of the model, the correction amount determination unit determines the correction amount based on the discharge amount estimated by the discharge amount estimation unit during modeling of the object. The molding apparatus according to claim 1 .

10. a discharge amount estimating unit that estimates a discharge amount of the modeling material to be discharged onto the table by the discharge head based on the modeling data before modeling the model, the correction amount determination unit determines the correction amount based on the discharge amount estimated by the discharge amount estimation unit before the object is formed. The molding apparatus according to claim 1 .

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