Three-dimensional printing apparatus and printing method

Abstract

The present invention provides a three-dimensional 3D printing apparatus and method that can improve printing quality while increasing printing efficiency. [Solution] The three-dimensional molding apparatus creates a three-dimensional object by extruding a molding material. The three-dimensional molding apparatus comprises an extruder 3 for extruding the molding material, an imaging device 6 for imaging the discharge state of the molding material discharged from the extruder 3, and a control device 7 for controlling the extruder 3. The control device 7 includes an operation control unit 72 that controls the operation of the extruder in a predetermined operation pattern, an acquisition unit 73 that acquires image data of the discharge state captured by the imaging device 6, and an adjustment unit 75 that adjusts the predetermined operation pattern based on the image data of the discharge state acquired by the acquisition unit 73. The operation control unit 72 operates the extruder 3 in the operation pattern adjusted by the adjustment unit 75.

Description

Technical Field

[0001] The present invention relates to a three-dimensional shaping apparatus and a shaping method, and particularly to a three-dimensional shaping apparatus that extrudes a shaping material to form a three-dimensional shaped object and a shaping method that forms a three-dimensional shaped object by a computer.

Background Art

[0002] Conventionally, 3D printer technology has been known that can form a three-dimensional shaped object by laminating and arranging a three-dimensional shaping material three-dimensionally using 3D-CAD (Computer Aided Design) data created on a computer as a design drawing. For example, 3D printer technology based on a fused deposition modeling (FDM) method is widely known, in which a thermoplastic resin used as a three-dimensional shaping material is heat-melted and extruded from a nozzle portion of an extruder, and shaped while being laminated on a work stage.

[0003] Patent Document 1 discloses an extruder that discharges a shaping material housed in a cylinder portion from a nozzle portion. This extruder has a plurality of measurement portions that measure pressure or temperature in a flow path of the shaping material, and identifies the state of the shaping material by the measurement portions. Then, the extruder determines whether the identified state of the shaping material is within an allowable range, and adjusts the temperature of a heater when it is outside the allowable range.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0005] Generally, the operating pattern of an extruder is designed by simulating it based on the shape of the object to be printed and the material used. The print quality of a 3D printer varies depending on factors such as the state of the material before extrusion, as well as the speed, position, and extrusion volume of the nozzle. However, while extruders like the one described in Patent Document 1 specify the state of the material inside the cylinder, they cannot specify the state of the material after it has been extruded from the nozzle. Furthermore, if an operator wanted to visually inspect the extruded material and adjust the parameters related to the extruder's operation, the printing process had to be stopped, and the operator had to manually adjust parameters such as the nozzle speed, position, and extrusion volume. This could potentially reduce printing efficiency.

[0006] The object of the present invention is to provide a three-dimensional molding apparatus and a molding method that can improve molding quality while increasing molding efficiency. [Means for solving the problem]

[0007] The aforementioned problems are solved by the three-dimensional molding apparatus of the present invention, which molds a three-dimensional object by extruding a molding material, comprising: an extruder for extruding the molding material; an imaging device for imaging the discharge state of the molding material discharged from the extruder; and a control device for controlling the extruder, wherein the control device comprises: an operation control unit for controlling the operation of the extruder; an acquisition unit for acquiring image data of the discharge state captured by the imaging device; and an adjustment unit for adjusting parameters related to the operation of the extruder based on the image data of the discharge state acquired by the acquisition unit, and the operation control unit controls the operation of the extruder based on the parameters related to the operation of the extruder adjusted by the adjustment unit.

[0008] With the above configuration, the extrusion state of the molding material discharged from the extruder can be imaged, and the operating parameters of the extruder can be automatically adjusted based on the image data of the extrusion state. Therefore, operators do not need to manually adjust the extruder's operating parameters, improving both build quality and build efficiency.

[0009] In this case, the extruder has a cylinder section for containing the molding material, a screw section provided inside the cylinder section for dispensing the molding material toward the tip of the cylinder section, and a nozzle section connected to the tip of the cylinder section for discharging the molding material dispensed by the screw section. The adjustment section may adjust at least one of the following parameters: the horizontal movement speed of the nozzle section, the height position of the nozzle section, and the rotational speed of the screw section. With the above configuration, the movement speed, height position, and rotation speed of the screw section, which have a particularly significant impact on the build quality, can be automatically adjusted, thereby further improving build quality and increasing build efficiency.

[0010] In this case, the imaging device captures the extrusion state of the molding material in real time, the acquisition unit acquires the image data of the extrusion state captured by the imaging device in real time, and the adjustment unit adjusts the parameters in real time. With the above configuration, the operating parameters of the extruder can be adjusted in real time, thereby further improving the quality of the printed parts.

[0011] In this case, the control device includes an image data storage unit that stores normal image data when the discharge state is normal, and a determination unit that compares the normal image data stored in the image data storage unit with the discharge state image data acquired by the acquisition unit to determine whether the discharge state is normal. The adjustment unit may adjust at least one of the moving speed, height position, and rotation speed based on the normal image data and the discharge state image data acquired by the acquisition unit when the determination unit determines that the discharge state is not normal. With the above configuration, the operating parameters of the extruder can be adjusted based on normal image data and image data of the ejection state, thereby improving the adjustment accuracy. Consequently, the molding quality can be further improved.

[0012] In this case, the control device includes an image storage unit that stores the image data of the ejection state acquired from the acquisition unit in the image data storage unit, and an image analysis unit that uses a machine learning model to analyze the relationship between the normal image data stored in the image data storage unit and the image data of the ejection state stored by the image storage unit and the parameters, and the determination unit may determine whether the ejection state is normal based on the analysis results of the image analysis unit. With the above configuration, it is possible to accurately determine whether the ejection state is normal by using image data analyzed by machine learning.

[0013] In this case, when the determination unit determines that the discharge state is not normal, the adjustment unit may adjust at least one of the moving speed, height position, and rotation speed based on the analysis results of the image analysis unit. With the above configuration, the operating parameters of the extruder can be precisely adjusted by using the results of analyzing the relationship between image data and the operating parameters of the extruder through machine learning.

[0014] Furthermore, the aforementioned problems are solved by the present invention's molding method, which is a molding method for molding a three-dimensional object using a computer, wherein the computer operates an extruder that extrudes a molding material, acquires image data of the ejection state of the molding material ejected from the extruder captured by an imaging device, adjusts parameters related to the operation of the extruder based on the acquired image data of the ejection state, and controls the operation of the extruder based on the adjusted parameters. With the above configuration, the extrusion state of the molding material discharged from the extruder can be imaged, and the operating parameters of the extruder can be automatically adjusted based on the image data of the extrusion state. Therefore, operators do not need to manually adjust the extruder's operating parameters, improving both build quality and build efficiency. [Effects of the Invention]

[0015] According to the three-dimensional shaping apparatus and shaping method of the present invention, it is possible to improve the shaping efficiency while improving the shaping quality.

Brief Description of the Drawings

[0016] [Figure 1] It is a perspective view of a three-dimensional shaping apparatus. [Figure 2] It is a cross-sectional view of an extruder and is a diagram for explaining the structure of the tip portion. [Figure 3] It is a diagram showing an image captured by an imaging device. [Figure 4] It is a block diagram of a three-dimensional shaping apparatus. [Figure 5A] It is a side view of the discharged shaping material and is a diagram showing the state when the discharge state is normal. [Figure 5B] It is a top view of the discharged shaping material and is a diagram showing the state when the discharge state is normal. [Figure 6A] It is a side view of the discharged shaping material and is a diagram showing the state when the discharge amount is small. [Figure 6B] It is a top view of the discharged shaping material and is a diagram showing the state when the discharge amount is small. [Figure 7A] It is a side view of the discharged shaping material and is a diagram showing the state when the discharge amount is large. [Figure 7B] It is a top view of the discharged shaping material and is a diagram showing the state when the discharge amount is large. [Figure 8] It is an explanatory diagram for calculating the discharge amount of the shaping material. [Figure 9] It is a control flow diagram.

Embodiments for Carrying Out the Invention

[0017] Hereinafter, a three-dimensional molding apparatus 1 of one embodiment of the present invention (hereinafter referred to as "this embodiment") will be described based on Figures 1 to 9. This embodiment relates to a three-dimensional molding apparatus and molding method that extrudes a molding material to create a three-dimensional object, and is capable of improving molding quality while increasing molding efficiency.

[0018] <Three-dimensional printing equipment> The three-dimensional molding apparatus 1 is a device that extrudes a molding material Ma to create a three-dimensional object M. Specifically, the three-dimensional molding apparatus 1 is a 3D printer that creates three-dimensional objects by stacking two-dimensional layers sliced ​​based on 3D-CAD data. As shown in Figure 1, the three-dimensional molding apparatus 1 comprises a work stage 2 used for the molding process, an extruder 3 that stacks the molding material Ma onto the work stage 2, a supply device 4 that supplies the molding material Ma to the extruder 3, a manipulator 5 that moves the extruder 3, an imaging device 6 that images the discharge state of the molding material Ma discharged from the extruder 3, and a control device 7 that controls the extruder 3, the supply device 4, the manipulator 5, and the imaging device 6.

[0019] Work stage 2 is a stage for creating a three-dimensional object M, and is used for the manufacturing process by the extruder 3.

[0020] The extruder 3 is a device that builds a three-dimensional object M by layering the molding material Ma onto the work stage 2. Examples of the molding material Ma include thermoplastic resin pellets. The pellets are heated and melted inside the extruder 3 and then extruded from the extruder 3. The heated and melted pellets are then deposited on the work stage 2, where they are cooled and hardened.

[0021] The supply device 4 is a device that supplies the molding material Ma to the extruder 3. The supply device 4 stores pellets and supplies the required amount to the extruder 3 via the control device 7.

[0022] The manipulator 5 is a robotic arm used to move the extruder 3. The extruder 3 is attached to the tip of the manipulator 5. By using the manipulator 5, work efficiency can be improved even when creating large three-dimensional objects M. When the extruder 3 is attached to the tip of the manipulator 5, the manipulator 5 moves the extruder 3 onto the work stage 2 to perform the molding operation. Parameters related to the operation of the extruder 3 (specifically, the movement speed and height position of the nozzle section 30) are adjusted by controlling the drive motor of the manipulator 5.

[0023] The imaging device 6 is a camera for capturing images of the extrusion state of the molding material Ma extruded from the extruder 3. The imaging device 6 is attached to the extruder 3 as shown in Figure 2. Specifically, the imaging device 6 is attached near the nozzle section 30, which will be described later, and is positioned to capture images of the extrusion port 32 of the nozzle section 30 and the state in which the molding material Ma has been extruded and deposited. The imaging device 6 is not limited to being mounted on the extruder 3; for example, it may be mounted on the work stage 2 or the manipulator 5.

[0024] As shown in Figure 3, the imaging device 6 captures the extrusion state of the molding material Ma extruded from the extrusion port 32 of the extruder 3 in real time. Real-time imaging means capturing an image of a single molded object at predetermined points in the molding process. These predetermined points are, for example, points set at predetermined intervals in one layer of the molded object. Specifically, this could be one point for every 1 cm of extrusion distance, or one point for every 1 second of extrusion time. The data captured by the imaging device 6 may also be a video of the extrusion state of the molding material Ma extruded from the extrusion port 32 of the extruder 3.

[0025] The control device 7 is a computer that controls the extruder 3, the feeder 4, the manipulator 5, and the imaging device 6. The control device 7 acquires molding information for creating the three-dimensional object M and controls the extruder 3, the feeder 4, the manipulator 5, and the imaging device 6. Specifically, the control device 7 controls the nozzle section 30 and manipulator 5 of the extruder 3 based on a predetermined operation pattern (for example, molding information such as coordinate information like G-code, speed information, and discharge amount information). The control device 7 also controls the supply device 4 based on a predetermined material pattern (for example, material information such as supply amount information and color information entered by the operator).

[0026] <Extruder> As shown in Figure 2, the extruder 3 includes a cylinder section 10 for containing the molding material Ma, a screw section 20 for dispensing the molding material Ma, a nozzle section 30 for ejecting the molding material Ma, and a plurality of heating sections 40 for heating the molding material Ma contained in the cylinder section 10.

[0027] The molding material Ma, melted in the cylinder section 10, is fed from the cylinder section 10 to the nozzle section 30 by the screw section 20 and extruded from the nozzle section 30. The molding material Ma extruded from the nozzle section 30 is then repeatedly layered on the work stage 2 to create a three-dimensional object M. Furthermore, the molding material Ma is not limited to pellets that have been heated and melted within the cylinder section 10. For example, the molding material Ma may be filament that has been melted by the frictional heat of the screw section 20.

[0028] The cylinder section 10 has a cylindrical shape and houses the molding material Ma and the screw section 20 inside. The cylinder section 10 is connected to the supply device 4, and pellet-shaped molding material Ma is supplied from the top. Multiple heating units 40 are provided in the cylinder section 10. The heating units 40 melt the pellet-shaped molding material Ma inside the cylinder section 10. Note that the configuration is not limited to melting inside the cylinder section 10; the molten molding material Ma may also be supplied inside the cylinder section 10. A detection sensor for detecting the internal pressure of the cylinder section 10 may be provided at the tip 11 of the cylinder section 10.

[0029] The screw section 20 is located inside the cylinder section 10 and delivers the molding material Ma toward the tip section 11 of the cylinder section 10. Specifically, the screw section 20 is the main screw that melts and mixes the pellet-shaped molding material Ma supplied from the supply device 4 inside the cylinder section 10. The screw section 20 rotates with its axis of rotation in the vertical direction, thereby delivering the molding material Ma downward toward the nozzle section 30. A motor (not shown) is connected to the screw section 20, and the motor is driven by the control device 7, causing the screw section 20 to rotate. The amount of drive of the motor is controlled by the control device 7, thereby adjusting the amount of molding material Ma extruded from the nozzle section 30. In other words, the parameters related to the operation of the extruder 3 (specifically, the rotational speed of the screw section 20) are adjusted by controlling the drive motor of the screw section 20.

[0030] The nozzle section 30 is connected to the tip 11 of the cylinder section 10 and is a nozzle that discharges the molding material Ma supplied by the screw section 20. The nozzle section 30 has a nozzle passage 31 connected to the tip 11 of the cylinder section 10 and an outlet 32 ​​for discharging the molding material Ma supplied from the nozzle passage 31. The tip 11 of the cylinder section 10 and the nozzle passage 31 are in communication. The molding material Ma supplied by the screw section 20 passes through the nozzle passage 31 in a molten state and is discharged onto the work stage 2 from the outlet 32.

[0031] Multiple heating units 40 are provided on the cylinder section 10 and are heaters for melting the pellet-shaped molding material Ma supplied to the cylinder section 10. For example, six heating units 40 are arranged along the side of the cylinder section 10, but their positions and number are not limited to this.

[0032] <Control by a control device> As shown in Figure 1, the control device 7 is, for example, a notebook PC, and incorporates a control circuit that controls the extruder 3, the supply device 4, the manipulator 5, and the imaging device 6. The control device 7 is electrically connected to the extruder 3, the supply device 4, the manipulator 5, and the imaging device 6. Each component is connected to the others via a bus so that they can communicate with each other.

[0033] <Hardware Configuration> The control device 7 has a control circuit and is mainly composed of a CPU (Central Processing Unit) which is a central processing unit, and storage devices such as ROM (Read Only Memory), RAM (Random Access Memory), and HDD (Hard Disk Drive).

[0034] The CPU (processor) is a central processing unit that executes various programs and controls various components. Specifically, the CPU reads programs from ROM or HDD and executes them using RAM as a workspace. The CPU controls each component and performs various calculations according to the programs stored in ROM or HDD.

[0035] ROM stores various programs and data. RAM temporarily stores programs or data as a working area. The HDD may also be an SSD (Solid State Drive), and it stores various programs, including the operating system, and various data.

[0036] <About the functions of the control device> Next, the functions of the control device 7 will be explained with reference to Figure 4. The functions of the control device 7 are realized through the cooperation of the hardware components (specifically, the CPU and memory) that constitute the control device 7 with the software components (control circuit). The control device 7 includes a storage unit 70 for storing predetermined operation patterns, an image data storage unit 71 for storing normal image data, an operation control unit 72 for controlling the operation of the extruder 3, an acquisition unit 73 for acquiring image data of the discharge state, a determination unit 74 for determining whether the discharge state is normal, an adjustment unit 75 for adjusting parameters related to the operation of the extruder 3, an image storage unit 76 for accumulating image data of the discharge state in the image data storage unit 71, and an image analysis unit 77 for analyzing the relationship between image data and parameters using machine learning. The storage unit 70 also stores information other than operation patterns (for example, the slicer software and image recognition judgment algorithm programs described later).

[0037] (Storage unit 70) The memory unit 70 stores various data necessary to start the molding process. Specifically, it stores a predetermined operation pattern (specifically, G-code) converted from the 3D data of the three-dimensional object M to be molded. More specifically, the control device 7 reads the 3D data of the three-dimensional object M to be fabricated, converts it into an operation pattern for three-dimensional fabrication using slicer software, and stores this converted operation pattern in the storage unit 70. The slicer software divides the target shape of the three-dimensional object M into layers of predetermined thickness and creates an operation pattern for each layer. The predetermined operation pattern is, for example, a G-code and includes operation commands, coordinate information of the nozzle section 30 of the extruder 3 for each divided layer, the discharge amount of the fabrication material Ma, and the feed rate of the fabrication material Ma. In other words, when fabrication is started, the parameters related to the operation of the extruder 3 (specifically, the movement speed and height position of the nozzle section 30, and the rotation speed of the screw section 20) are determined based on the G-code stored in the storage unit 70.

[0038] (Image data storage unit 71) The image data storage unit 71 stores normal image data when the ejection state is normal. In other words, the image data storage unit 71 stores a large amount of ideal image data of when the object is fabricated normally based on the G-code set in the simulation. Specifically, as shown in Figures 5A and 5B, the image data storage unit 71 stores data of the shape of the fabrication material Ma that has been deposited normally based on the G-code. Here, "normal extrusion of the printing material Ma" means that the model was printed correctly based on the G-code, and the printing material Ma was extruded uniformly and evenly without any breaks or undulations in the printed surface. "Abnormal extrusion of the printing material Ma" means that, as shown in Figures 6A and 6B, the amount of printing material Ma extruded is too little, resulting in a broken or small printed surface as in patterns P1 to P3. Also, as shown in Figures 7A and 7B, "abnormal extrusion of the printing material Ma" means that the amount of printing material Ma extruded is too much, resulting in a wavy or uneven printed surface as in pattern P4, or a spread-out printed surface as in pattern P5.

[0039] The image data storage unit 71 may also store abnormal image data when the ejection state is not normal. In this case, the image data storage unit 71 stores a large amount of image data when the molding was not performed correctly based on the G-code. Specifically, the image data storage unit 71 stores data of the shape of the molding material Ma that was not deposited correctly based on the G-code. Of course, it may also store data for both normal and abnormal image data.

[0040] Furthermore, the image data storage unit 71 stores image data of the extrusion state of the molding material Ma captured by the imaging device 6 via the image storage unit 76. The image data storage unit 71 stores image data of the extrusion state of the molding material Ma captured by the imaging device 6 in real time. As shown in Figure 3, the imaging device 6 captures the extrusion state of the molding material Ma from an oblique angle above. However, in order to reduce the amount of data, the image data storage unit 71 stores images converted to a side view as shown in Figure 5A and a top view as shown in Figure 5B. However, it is not limited to this, and images captured from an oblique angle above may also be stored.

[0041] (Operation control unit 72) The motion control unit 72 controls the operation of the extruder 3 according to a predetermined operation pattern stored in the memory unit 70. Specifically, the motion control unit 72 drives the screw unit 20 and manipulator 5 of the extruder 3 based on the G code, and controls the horizontal movement speed of the nozzle unit 30, the height position of the nozzle unit 30, and the rotational speed of the screw unit 20, respectively. The horizontal movement speed and height position of the nozzle section 30 are changed by the operation of the manipulator 5. The rotational speed of the screw section 20 is changed by the drive of a motor (not shown) connected to the screw section 20.

[0042] The operation control unit 72 controls the operation of the extruder 3 based on parameters related to the operation of the extruder 3 determined by the G code when starting molding or when the extrusion state of the molding material Ma is normal. Furthermore, when the extrusion state of the molding material Ma is not normal, the operation control unit 72 controls the operation of the extruder 3 based on parameters related to the operation of the extruder 3 adjusted by the adjustment unit 75. Specifically, the operation control unit 72 controls the extruder 3 using the horizontal movement speed of the nozzle unit 30, the height position of the nozzle unit 30, and the rotation speed of the screw unit 20, which are adjusted by the adjustment unit 75.

[0043] (Acquisition part 73) The acquisition unit 73 acquires image data of the extrusion state of the molding material Ma captured by the imaging device 6. Specifically, it acquires the shape of the molding material Ma extruded from the nozzle unit 30 and deposited. In this embodiment, the system is configured to acquire only the shape of the deposited molding material Ma from the image captured by the imaging device 6. That is, it does not acquire information other than the deposited molding material Ma (for example, the shape of the work stage 2 or the nozzle unit 30). The shape of the deposited molding material Ma is identified by the image recognition judgment algorithm program stored in the storage unit 70. By acquiring only the shape of the deposited molding material Ma, the judgment accuracy of the judgment unit 74 and the processing speed can be improved. The acquisition unit 73 may acquire the shape of the work stage 2 or the nozzle unit 30, or it may acquire all information from the image captured by the imaging device 6, not limited to the shape.

[0044] The acquisition unit 73 acquires image data of the extrusion state of the molding material Ma captured by the imaging device 6 in real time. Real-time acquisition means acquiring data for each molded object at predetermined points in the molding process.

[0045] (Judgment unit 74) The determination unit 74 determines whether the ejection state is normal based on the ejection state image data acquired by the acquisition unit 73. Specifically, the determination unit 74 compares the normal image data stored in the image data storage unit 71 with the ejection state image data acquired by the acquisition unit 73 to determine whether the ejection state of the molding material Ma is normal. More specifically, the determination unit 74 compares the ideal shape of the molding material Ma in the normal image data with the actual shape of the extruded molding material Ma and determines whether it meets the acceptable range. "Meeting the acceptable range" includes cases where the shapes are perfectly identical or where the difference in shape falls within a predetermined range.

[0046] The determination unit 74 determines that the extrusion state of the extruded molding material Ma is normal if the shape of the extruded molding material Ma meets the acceptable range. On the other hand, if it does not meet the predetermined acceptable range, the determination unit 74 determines that the extrusion state of the molding material Ma is not normal. For example, if the shape of the extruded molding material Ma is smaller than the shape of the normal image data, it is determined that the extrusion amount is insufficient, and if a waveform appears on the extrusion surface or if the shape of the extruded molding material Ma is larger than the normal image data, it is determined that the extrusion amount is excessive.

[0047] The determination unit 74 determines in real time whether the ejection state is normal based on the ejection state image data acquired by the acquisition unit 73. Real-time determination means that each time the acquisition unit 73 acquires image data of the ejection state of the molding material Ma, the determination unit 74 determines whether the ejection state is normal. Furthermore, the determination unit 74 is not limited to making a determination each time the acquisition unit 73 acquires image data of the extrusion state of the molding material Ma, but may also make a determination by comprehensively analyzing image data of the extrusion state at multiple predetermined points.

[0048] (Adjustment section 75) The adjustment unit 75 adjusts parameters related to the operation of the extruder 3 based on image data of the discharge state acquired by the acquisition unit 73. Specifically, the adjustment unit 75 adjusts at least one of the following parameters based on the normal image data and the image data of the discharge state acquired by the acquisition unit 73: the horizontal movement speed of the nozzle unit 30, the height position of the nozzle unit 30, and the rotation speed of the screw unit 20. More specifically, when the determination unit 74 determines that the extrusion state is not normal, the adjustment unit 75 compares the ideal shape of the molding material Ma in the normal image data with the actual shape of the extruded molding material Ma, and calculates the extent of deviation in each parameter based on the difference in each shape. Then, the adjustment unit 75 corrects the parameters of the movement speed and height position of the nozzle unit 30 and the rotation speed parameter of the screw unit 20 to the optimal parameters determined by the calculation.

[0049] In 3D printing technology, the printing quality is determined by equation (1), which represents information I of the layer pitch g normalized by the nozzle diameter D, and equation (2), which represents the nozzle movement speed V (i.e., printing speed P) normalized by the nozzle outlet flow velocity U (see Figure 8). I = g / D ... (1) P = V / U ... (2) Normally, molding quality can be improved by controlling the extrusion rate, but it is difficult to determine the optimal parameter due to the influence of factors such as the specific gravity and melting point of the material used. Therefore, the adjustment unit 75 can calculate the optimal parameter E using equation (3) of the calculation algorithm and adjust it automatically. E = (4 w. h L) / π D 2 ...(3) As shown in Figure 8, w represents the width of the extruded molding material Ma, h represents the height of the extruded molding material Ma, and L represents the length of the extruded molding material Ma.

[0050] When the extrusion state of the molding material Ma is not normal, the adjustment unit 75 adjusts the movement speed of the nozzle unit 30, the height position of the nozzle unit 30, and the rotation speed of the screw unit 20 to the optimal parameters. Then, the operation control unit 72 controls the operation of the extruder 3 based on the parameters of the movement speed of the nozzle unit 30, the height position of the nozzle unit 30, and the rotation speed of the screw unit 20 that have been adjusted by the adjustment unit 75. The adjustment unit 75 may adjust all of the parameters, including the movement speed of the nozzle unit 30, the height position of the nozzle unit 30, and the rotation speed of the screw unit 20, or it may adjust only one of these parameters. The adjustment unit 75 may also adjust other parameters related to the operation of the extruder 3, such as adjusting the set temperature of the heating unit 40.

[0051] The adjustment unit 75 compares the normal image data stored in the image data storage unit 71 with the discharge state image data acquired by the acquisition unit 73 and adjusts the parameters related to the operation of the extruder 3 in real time. Real-time adjustment means that each time the determination unit 74 determines whether the discharge state is normal, the adjustment unit 75 adjusts the parameters. Furthermore, the adjustment unit 75 is not limited to a configuration that adjusts the parameters each time the determination unit 74 determines that the discharge state is not normal; for example, it may adjust the parameters when the discharge state is repeatedly determined to be abnormal.

[0052] In this embodiment, the adjustment unit 75 can change the operation of the extruder 3 by adjusting parameters related to the operation of the extruder 3, thereby changing the operation of the extruder 3 without modifying the read G-code. Therefore, since there is no need to repeat the process of reading the G-code, the molding efficiency can be further improved. However, the adjustment unit 75 is not limited to this, and may also change the G-code itself.

[0053] (Image storage unit 76) The image storage unit 76 stores the ejection state image data acquired from the acquisition unit 73 in the image data storage unit 71. Specifically, the image storage unit 76 stores the ejection state image data of the molding material Ma captured by the imaging device 6, linked to the operation pattern at the time of ejection and whether or not the ejection state was normal. More specifically, the image storage unit 76 stores, in association with the image data of the ejection state of the molding material Ma captured by the imaging device 6, the parameters defined by the G code, the information determined by the determination unit 74 regarding whether the ejection state was normal or not, and the parameters adjusted by the adjustment unit 75.

[0054] The image storage unit 76 stores image data of the ejection state of the molding material Ma, captured by the imaging device 6, in real time in the image data storage unit 71. Real-time storage means that each time the determination unit 74 determines whether the ejection state is normal, the image storage unit 76 stores the image data of the ejection state acquired from the acquisition unit 73 in the image data storage unit 71. Furthermore, the image storage unit 76 is not limited to a configuration in which it stores image data of the ejection state in the image data storage unit 71 each time the determination unit 74 determines that the ejection state is not normal. For example, it may also store image data of the ejection state in the image data storage unit 71 when it is repeatedly determined that the ejection state is not normal.

[0055] (Image Analysis Department 77) The image analysis unit 77 uses a machine learning model to analyze the relationship between normal image data stored in the image data storage unit 71 and image data of the discharge state stored by the image storage unit 76, and parameters related to the operation of the extruder 3. Specifically, it generates an estimation model to determine whether the discharge state is normal or not by using machine learning with image data of the normal discharge state and image data of the abnormal discharge state as training images. The determination unit 74 determines whether the discharge state is normal based on the analysis results of the image analysis unit 77. When the determination unit 74 determines that the discharge state is not normal, the adjustment unit 75 adjusts at least one of the following based on the analysis results of the image analysis unit 77: the movement speed of the nozzle unit 30, the height position, and the rotation speed of the screw unit 20.

[0056] Specifically, the image analysis unit 77 modifies the normal image data based on the analysis results of the image analysis unit 77. Then, the determination unit 74 determines whether the ejection state is normal based on the normal image data that has been modified based on the analysis results of the image analysis unit 77. Furthermore, the adjustment unit 75 compares the ideal shape of the molding material Ma in the normal image data, which has been modified based on the analysis results of the image analysis unit 77, with the actual shape of the extruded molding material Ma, and calculates the extent of deviation in each parameter based on the difference in each shape. Then, the adjustment unit 75 modifies the parameters of the movement speed and height position of the nozzle unit 30 and the rotation speed parameter of the screw unit 20 to the optimal parameters determined by the calculation. Note that the calculation formula for the optimal parameters may be changed based on the analysis results of the image analysis unit 77.

[0057] In this way, by using a machine learning model to analyze the relationship between image data of the discharge state and parameters related to the operation of the extruder 3, the accuracy of the determination by the determination unit 74 and the accuracy of the calculation of optimal parameters by the adjustment unit 75 can be improved. While deep learning is preferred for the machine learning learning process, the type of machine learning is not limited to this.

[0058] <Flowchart of 3D modeling process> Next, the processing of the manufacturing method executed by the control device 7 of the three-dimensional molding apparatus 1 will be explained based on Figure 9. Figure 9 shows the flow of the manufacturing process for the three-dimensional object M. The manufacturing process for the three-dimensional object is performed by the CPU of the control device 7 executing the manufacturing process program for the three-dimensional object M stored in the memory unit.

[0059] As shown in Figure 9, the control device 7 starts the fabrication of the three-dimensional object M (step S1). Specifically, the control device 7 reads the 3D data of the three-dimensional object M to be fabricated. Then, it converts the data into data for three-dimensional fabrication using slicer software and outputs an operation pattern. For example, the slicer software divides the target shape of the three-dimensional object M into layers of predetermined thickness and creates G-code for each layer. The motors of the extruder 3 and manipulator 5 are then controlled based on the G-code. Next, the control device 7 acquires image data of the extrusion state of the molding material Ma captured by the imaging device 6 using the acquisition unit 73 (step S2). As described above, the acquisition of image data of the extrusion state is performed in real time by the acquisition unit 73.

[0060] Next, the control device 7 compares the normal image data stored in the image data storage unit 71 by the determination unit 74 with the image data of the ejection state acquired by the acquisition unit 73 to determine whether the ejection state of the molding material Ma is normal or not (step S3). Then, the determination unit 74 of the control device 7 determines whether the ejection amount is less than that of the normal image data (step S4). Subsequently, the determination unit 74 determines whether the ejection amount is more than that of the normal image data (step S5). Then, if the ejection amount is normal compared to the normal image data (step S4: No, and step S5: No), the control device 7 determines that the parameters based on the operation pattern at that time are optimal, and stores in the image data storage unit 71 the image data of the ejection state of the molding material Ma captured by the imaging device 6, the parameters based on the operation pattern at that time, and the determination that the ejection state is normal as determined by the determination unit 74 (step S6). Then, the control device 7 continues the molding process without adjusting the parameters based on the operation pattern by the operation control unit 72 (step S7).

[0061] On the other hand, if the discharge volume is not normal compared to the normal image data (step S4: Yes or step S5: Yes), the control device 7 compares the normal image data stored in the image data storage unit 71 by the adjustment unit 75 with the discharge state image data acquired by the acquisition unit 73 and calculates parameters based on the operation pattern (step S8). Specifically, the control device 7 adjusts the parameters of the horizontal movement speed of the nozzle unit 30, the height position of the nozzle unit 30, and the rotation speed of the screw unit 20, respectively, based on the comparison result of the normal image data and the discharge state image data acquired by the acquisition unit 73. When the discharge volume is small, the adjustment unit 75 adjusts the parameters, for example, to increase the rotation speed of the screw unit 20. Also, when the discharge volume is large, the adjustment unit 75 adjusts the parameters, for example, to increase the movement speed of the nozzle unit 30. The control device 7 then stores in the image data storage unit 71 the image data storage unit 71, linking the image data of the ejection state of the molding material Ma captured by the imaging device 6, the parameters of the operation pattern defined by the G code, the determination that the ejection state is not normal as determined by the determination unit 74, and the parameters adjusted by the adjustment unit 75 (step S9). The control device 7 then continues the molding process based on the parameter values ​​of the operation pattern adjusted by the adjustment unit 75, with the operation control unit 72 (step S7). In this embodiment, the adjustment unit 75 adjusts the horizontal movement speed of the nozzle unit 30, the height position of the nozzle unit 30, and the rotation speed of the screw unit 20, respectively, according to the determination result of the determination unit 74. However, the system is not limited to this, and the adjustment unit 75 may always adjust each parameter without making a determination by the determination unit 74.

[0062] In this method of creating three-dimensional objects using a computer, the control device 7, acting as a computer, executes each of the steps described above. Specifically, the operation control unit 72 of the control device 7 operates the extruder 3 that extrudes the molding material Ma. The acquisition unit 73 of the control device 7 acquires image data of the extrusion state of the molding material Ma ejected from the extruder 3, which is captured by the imaging device 6. The adjustment unit 75 of the control device 7 adjusts the parameters related to the operation of the extruder 3 based on the acquired image data of the extrusion state. The operation control unit 72 of the control device 7 then controls the operation of the extruder 3 based on the parameters adjusted by the adjustment unit 75. Therefore, the operator does not need to manually adjust the operating parameters of the extruder 3, and it is possible to improve molding quality while increasing molding efficiency.

[0063] In the above embodiments, the three-dimensional molding apparatus and molding method according to the present invention were mainly described. However, the embodiments described above are merely examples to facilitate understanding of the present invention and do not limit it. The present invention can be modified and improved without departing from its spirit, and of course, equivalents thereof are included. In particular, the embodiments described above are merely examples and do not limit the present invention. [Explanation of Symbols]

[0064] 1 3D printing equipment 2 Work Stages 3. Extruder 4 Feeding device 5 Manipulators 6. Imaging device 7. Control device (computer) 10 Cylinder section 11 Tip 20 Screw section 30 Nozzle section 31 Nozzle passage 32 Discharge port 40 Heating section 70 Storage section 71 Image data storage unit 72 Operation Control Unit 73 Acquisition Department 74 Judgment section 75 Adjustment section 76 Image storage unit 77 Image Analysis Department M Three-dimensional object Ma modeling material

Claims

1. A three-dimensional molding apparatus that extrudes molding material to create a three-dimensional object, An extruder for extruding the aforementioned molding material, An imaging device for imaging the ejection state of the molding material ejected from the extruder, The system comprises a control device for controlling the extruder, The control device is The operation control unit controls the operation of the extruder, An acquisition unit that acquires image data of the ejection state captured by the imaging device, The system includes an adjustment unit that adjusts parameters related to the operation of the extruder based on the image data of the discharge state acquired by the acquisition unit, The three-dimensional molding apparatus is characterized in that the operation control unit controls the operation of the extruder based on the parameters relating to the operation of the extruder that have been adjusted by the adjustment unit.

2. The extruder is, A cylinder section for housing the molding material, A screw portion is provided inside the cylinder portion and is used to feed the molding material toward the tip of the cylinder portion, It has a nozzle portion connected to the tip of the cylinder portion, which discharges the molding material that has been delivered by the screw portion, The three-dimensional molding apparatus according to claim 1, characterized in that the adjustment unit adjusts at least one of the following parameters: the horizontal movement speed of the nozzle portion, the height position of the nozzle portion, and the rotation speed of the screw portion.

3. The imaging device captures the extrusion state of the molding material in real time. The acquisition unit acquires the image data of the ejection state captured by the imaging device in real time. The three-dimensional molding apparatus according to claim 1 or 2, characterized in that the adjustment unit adjusts the parameters in real time.

4. The control device is An image data storage unit that stores normal image data when the discharge state is normal, The system includes a determination unit that compares the normal image data stored in the image data storage unit with the image data of the ejection state acquired by the acquisition unit to determine whether the ejection state is normal. The three-dimensional molding apparatus according to claim 2, characterized in that when the determination unit determines that the ejection state is not normal, the adjustment unit adjusts at least one of the moving speed, the height position, and the rotation speed based on the normal image data and the image data of the ejection state acquired by the acquisition unit.

5. The control device is An image storage unit that stores the image data of the discharge state acquired from the acquisition unit in the image data storage unit, The system includes an image analysis unit that uses a machine learning model to analyze the relationship between the normal image data stored in the image data storage unit, the image data of the ejection state stored by the image storage unit, and the parameters, The three-dimensional molding apparatus according to claim 4, characterized in that the determination unit determines whether the ejection state is normal based on the analysis results of the image analysis unit.

6. The three-dimensional molding apparatus according to claim 5, characterized in that when the determination unit determines that the ejection state is not normal, the adjustment unit adjusts at least one of the moving speed, the height position, and the rotation speed based on the analysis result of the image analysis unit.

7. A method of creating three-dimensional objects using a computer, The aforementioned computer, Operating the extruder that pushes out the molding material, To acquire image data of the extrusion state of the molding material extruded from the extruder, captured by the imaging device, Based on the acquired image data of the discharge state, the parameters related to the operation of the extruder are adjusted, A molding method characterized by controlling the operation of the extruder based on the adjusted parameters.

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