Numerical control device and numerical control method

Abstract

An NC device (1) is provided with: an additive manufacturing execution unit (103) which controls an additive manufacturing process in which a modeled object is manufactured by layering materials melted by irradiation with a beam; a removal manufacturing execution unit (107) which controls a removal manufacturing process in which a modeled object is cut using a tool; a state analysis unit (104) which analyzes the machining state of a modeled object manufactured by a combination of two production processes, namely, an additive manufacturing process and a removal manufacturing process, on the basis of sensor data (24) obtained by monitoring the machining state of the modeled object; a production process change unit (105) which, on the basis of the machining state analysis result, outputs, to the additive manufacturing execution unit and the removal manufacturing execution unit, a switching command that indicates switching to the execution of one of the two production processes; and a process condition generation unit (106) which, in the switching between the two production processes, determines the process conditions used in the post-switching production process on the basis of the process conditions used in the pre-switching production process.

Description

[Technical field]

[0001] The present disclosure relates to a numerical control device and a numerical control method for controlling additive manufacturing devices and subtractive manufacturing devices. [Background technology]

[0002] Additive manufacturing equipment is known that manufactures three-dimensional objects using the Direct Energy Deposition (DED) method. One type of additive manufacturing equipment melts material locally using a beam emitted from a processing head, and adds the melted material to a workpiece. Additive manufacturing equipment can manufacture complex shapes such as hollow structures and one-piece moldings, but the manufacturing accuracy is low, so it is necessary to remove undesired areas using a subtractive manufacturing equipment. Subtractive manufacturing equipment manufactures desired shapes by cutting the workpiece using various cutting tools such as drills and milling cutters attached to the processing head. Subtractive manufacturing equipment can manufacture objects with higher accuracy than additive manufacturing.

[0003] When additive manufacturing equipment and cutting manufacturing equipment are controlled by a numerical control device, the processing program input to the numerical control device is generally created by a computer-aided manufacturing (CAM) device. The numerical control device analyzes the processing program to determine a movement path for moving the processing head, and generates a position command that is a group of interpolation points for each unit time on the movement path. The numerical control device controls the operating mechanisms of the additive manufacturing equipment and cutting manufacturing equipment according to the position command. The numerical control device also generates commands according to the process conditions specified by the processing program.

[0004] The numerical controller controls the beam source by generating commands for the additive manufacturing device according to the beam power conditions. The numerical controller also controls the material supply source, such as metal powder or metal wire, by generating commands for the additive manufacturing device according to the material supply amount conditions. During additive manufacturing, the beam is irradiated onto the material and the workpiece, causing a portion of the workpiece to melt, and a molten pool of molten material is formed on the workpiece. The molten material is fed into the molten pool and solidifies, forming a layer of solidified molten material on the workpiece.

[0005] The numerical control device also generates commands according to the tool rotation speed conditions for the cutting manufacturing device to control the cutting edge of the cutting tool. The cutting manufacturing device physically cuts into the workpiece with the cutting edge of the cutting tool, and removes part of the workpiece as chips to form a cutting surface.

[0006] The method of generating control data described in Patent Document 1 determines a cutting path for cutting with a tool the shape to be generated by additive manufacturing technology, and a nozzle path for supplying material so as to reproduce the cutting path going back in time. [Prior art documents] [Patent documents]

[0007] [Patent Document 1] Patent No. 6626788 Summary of the Invention [Problem to be solved by the invention]

[0008] However, in the technology of Patent Document 1, the timing of switching between the cutting process and the additive manufacturing process is determined in advance using CAM based on the user's know-how, without taking into account the welding state of the metal material in the additive manufacturing process and the heat accumulation state of the processed part. Therefore, in the technology of Patent Document 1, even if the molded object is distorted or collapsed due to the welding state or heat accumulation state, the additive manufacturing process cannot be interrupted and the additive manufacturing process continues even if the molded object is distorted or collapsed. Therefore, the technology of Patent Document 1 has a problem in that it is not possible to accurately manufacture a desired molded object.

[0009] The present disclosure has been made in consideration of the above, and has an object to provide a numerical control device that can accurately manufacture a desired object. [Means for solving the problem]

[0010] In order to solve the above-mentioned problems and achieve the object, the numerical control device of the present disclosure includes an additive manufacturing execution unit that controls an additive manufacturing device that executes an additive manufacturing process for manufacturing a shaped object by stacking a material melted by irradiating a beam from a first processing head, and a subtractive manufacturing execution unit that controls a subtractive manufacturing device that executes a subtractive manufacturing process for cutting the shaped object using a tool arranged on a second processing head. The numerical control device of the present disclosure also includes a control unit that controls a subtractive manufacturing device that executes a subtractive manufacturing process for cutting the shaped object by combining two production processes, the additive manufacturing process and the subtractive manufacturing process. In production The numerical control device of the present disclosure includes a state analysis unit that receives sensor data obtained by monitoring the processing state and analyzes the processing state of the shaped object based on the sensor data, and a production process change unit that generates a switching command to instruct switching between two production processes to be executed based on the analysis result of the processing state and outputs the switching command to the additive manufacturing execution unit and the subtractive manufacturing execution unit. Additive Manufacturing Based on the first process conditions used in Elimination manufacturing processThe process condition generating unit determines the second process condition to be used in the process. Elimination manufacturing process A moving direction in the machining path used in Additive manufacturing process during production of the object Used in Ta The movement direction is opposite to the movement direction on the machining path. Effect of the Invention

[0011] The numerical control device according to the present disclosure has an effect of being able to accurately manufacture a desired object. [Brief description of the drawings]

[0012] [Figure 1] FIG. 1 shows an additive manufacturing device and a subtractive manufacturing device controlled by an NC device according to a first embodiment. [Diagram 2] FIG. 1 is a diagram showing a functional configuration of an NC device according to a first embodiment. [Diagram 3] 1 is a flowchart showing a procedure of an operation performed by an NC device according to a first embodiment. [Figure 4] FIG. 2 is a diagram for explaining the welding state during modeling by the additive manufacturing apparatus shown in FIG. [Diagram 5] FIG. 1 is a diagram showing an example of a machining program used by the NC device according to the first embodiment; [Figure 6] FIG. 6 is a diagram showing an example of a model produced by additive manufacturing using the processing program shown in FIG. 5 by the NC device according to the first embodiment; [Figure 7] FIG. 1 is a diagram for explaining a relationship between temperature data of a processed part extracted as a feature amount during an additive manufacturing process by an NC device according to a first embodiment and a change in bead width; [Figure 8] FIG. 1 is a diagram for explaining a relationship between molten pool data of a processed part extracted as a feature amount during an additive manufacturing process by an NC device according to a first embodiment and a change in bead height. [Figure 9] FIG. 13 is a diagram showing a first example of a head movement path in a removal manufacturing process generated by the NC device according to the first embodiment when an effect of heat accumulation occurs; [Figure 10]FIG. 13 is a diagram showing a second example of a head movement path in the removal manufacturing process generated by the NC device according to the first embodiment when an effect of heat accumulation occurs; [Figure 11] FIG. 13 is a diagram showing a first example of a head movement path in the removal manufacturing process that is generated when the NC device according to the first embodiment is in a state where the deposition amount is insufficient. [Figure 12] FIG. 13 is a diagram showing a second example of a head movement path in the removal manufacturing process generated when the NC device according to the first embodiment is in a state of insufficient deposition amount; [Figure 13] FIG. 13 is a diagram showing a functional configuration of an NC device according to a second embodiment. [Figure 14] 11 is a flowchart showing a procedure of an operation performed by an NC device according to a second embodiment. [Figure 15] FIG. 13 is a diagram showing an example of a shaped object that is manufactured by the subtractive manufacturing device according to the second embodiment by the NC device; [Figure 16] FIG. 1 is a diagram showing an example of the configuration of a processing circuit provided in the NC device according to the first and second embodiments when the processing circuit is realized by a processor and a memory. [Figure 17] FIG. 1 is a diagram showing an example of a processing circuit in the NC device according to the first and second embodiments, in which the processing circuit is configured with dedicated hardware; DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0013] A numerical control device and a numerical control method according to embodiments of the present disclosure will be described in detail below with reference to the drawings. In the following description, the numerical control device will be referred to as an NC (Numerical Control) device.

[0014] Embodiment 1 1 is a diagram showing an additive manufacturing apparatus and a subtractive manufacturing apparatus controlled by an NC device according to embodiment 1. The processing system 60 is a system that produces a three-dimensional object 15. The processing system 60 includes an additive manufacturing apparatus 100, a subtractive manufacturing apparatus 102, an NC device 1, and an automatic transport device 101.

[0015] The additive manufacturing apparatus 100 is an additive apparatus that manufactures a three-dimensional object 15 by a directed energy deposition method. The additive manufacturing apparatus 100 is a machine tool that manufactures the object 15 by adding a material 5 melted by a beam emitted from a processing head 8 to a workpiece 16. The additive manufacturing apparatus 100 has a laser oscillator 2, a gas supply device 6, the processing head 8, a head drive device 12, a material supply device 4, and a stage 13.

[0016] The removal manufacturing apparatus 102, which is a removal manufacturing apparatus, is a machine tool that removes a portion of the object 15 to form the object 15 into a desired shape. An example of the removal manufacturing apparatus 102 is a cutting manufacturing apparatus. The removal manufacturing apparatus 102 has a spindle drive device 22, a processing head 21, a head drive device 20, and a stage 18. The processing head 8 is a first processing head, and the processing head 21 is a second processing head.

[0017] In the first embodiment, the beam used by the additive manufacturing apparatus 100 is a laser beam, and the material 5 is a metal material such as a metal wire. The material 5 used in the additive manufacturing apparatus 100 is not limited to a metal wire, and may be a metal powder.

[0018] The additive manufacturing apparatus 100 forms a model 15 on the surface of a base material 14 by stacking layers formed by solidifying the molten material 5. The base material 14 is placed on a stage 13. In the following description, the workpiece 16 is an object to which the molten material 5 is added, and refers to the base material 14 and the model 15. The base material 14 shown in FIG. 1 is a plate material. Note that the base material 14 may be a material other than a plate material.

[0019] The processing head 8 of the additive manufacturing apparatus 100 moves relative to the workpiece 16. The processing head 8 has a beam nozzle 9, a material nozzle 10, and a gas nozzle 11. The beam nozzle 9 emits a laser beam toward the workpiece 16. The material nozzle 10 advances the material 5 toward the irradiation position of the laser beam on the workpiece 16. The gas nozzle 11 injects gas toward the workpiece 16. The additive manufacturing apparatus 100 suppresses oxidation of the molded object 15 and cools the layer formed on the workpiece 16 by injecting gas.

[0020] A laser oscillator 2 serving as a beam source oscillates a laser beam. The laser beam from the laser oscillator 2 propagates through a fiber optic cable 3 serving as an optical transmission line to a beam nozzle 9. A gas supply device 6 supplies gas to a gas nozzle 11 through a pipe 7.

[0021] The material supply device 4 is a supply source of the material 5. The material supply device 4 has a drive unit for feeding the material 5, which is a metal wire. The material 5 fed from the material supply device 4 is supplied to the irradiation position of the laser beam via the material nozzle 10.

[0022] The head driving device 12 has a servo motor that constitutes an operating mechanism for moving the processing head 8. The head driving device 12 moves the processing head 8 in each of the X-axis direction, the Y-axis direction, and the Z-axis direction. The X-axis, the Y-axis, and the Z-axis are three axes perpendicular to each other. The X-axis and the Y-axis are axes parallel to the horizontal direction. The Z-axis direction is the vertical direction. In FIG. 1, the servo motors of the head driving device 12 are omitted. In the additive manufacturing apparatus 100, the head driving device 12 moves the processing head 8 to move the irradiation position of the laser beam on the workpiece 16.

[0023] The additive manufacturing apparatus 100 moves the irradiation position of the laser beam on the workpiece 16 by moving the processing head 8 relative to the workpiece 16. Note that the additive manufacturing apparatus 100 may move the irradiation position of the laser beam on the workpiece 16 by moving the workpiece 16 relative to the processing head 8. Note that in the following description, the irradiation position of the laser beam may be simply referred to as the "irradiation position."

[0024] The NC device 1 controls the additive manufacturing device 100 in accordance with a processing program. The NC device 1 controls the position of the processing head 8 driven by the head driver 12 by outputting a position command to the head driver 12. The NC device 1 controls the laser oscillation by the laser oscillator 2 by outputting an output command, which is a command according to the beam output conditions, to the laser oscillator 2.

[0025] The NC device 1 controls the material supply device 4 by outputting a supply command, which is a command according to the condition of the supply amount of material 5 (hereinafter sometimes referred to as metal supply amount), to the material supply device 4. When the material 5 is a metal wire, the supply command output by the NC device 1 may be a command according to the condition of the supply speed of the material 5. The supply speed is the speed of the material 5 moving from the material supply device 4 toward the irradiation position. The supply speed represents the amount of material 5 supplied per unit time.

[0026] The NC device 1 controls the amount of gas supplied from the gas supply device 6 to the gas nozzle 11 by outputting a command according to the conditions of the gas supply amount to the gas supply device 6. Note that the NC device 1 may be one of the components of the additive manufacturing apparatus 100, or may be an external device to the additive manufacturing apparatus 100.

[0027] The automatic transport device 101 removes the object 15 from the stage 13 of the additive manufacturing apparatus 100, and places it on the stage 18 of the subtractive manufacturing apparatus 102. The automatic transport device 101 also removes the object 15 from the stage 18 of the subtractive manufacturing apparatus 102, and places it on the stage 13 of the additive manufacturing apparatus 100.

[0028] The automatic transfer device 101 includes a hand driving device 25 and a hand mechanism 17. The hand driving device 25 has a servo motor constituting an operating mechanism for gripping a shaped object 15 fixed to a jig (not shown) via a base material 14 with the hand mechanism 17 and moving the shaped object 15 in each of the X-axis direction, Y-axis direction, and Z-axis direction. Note that illustration of each servo motor is omitted in FIG. 1. The NC device 1 controls the positions of the hand driving device 25 and the hand mechanism 17 by outputting a movement command to the automatic transfer device 101. Note that the NC device 1 may be one of the components of the automatic transfer device 101, or may be an external device to the automatic transfer device 101.

[0029] The subtractive manufacturing device 102 presses a rotating tool 19 against the object 15 to remove a portion of the object 15, thereby forming the object 15 into a desired shape. The head driving device 20 has a servo motor that constitutes an operating mechanism for moving the processing head 21. The head driving device 20 moves the processing head 21 in each of the X-axis direction, the Y-axis direction, and the Z-axis direction. In FIG. 1, the servo motors of the head driving device 20 are omitted from illustration.

[0030] In the removal manufacturing apparatus 102, the head driving device 20 moves the processing head 21 to move the tip position of the tool 19 relative to the workpiece 16. The spindle driving device 22 may be disposed inside the processing head 21 or outside the processing head 21. The spindle driving device 22 has a servo motor that constitutes an operating mechanism for rotating the tool 19. In FIG. 1, the servo motors of the spindle driving device 22 are omitted from illustration.

[0031] The subtractive manufacturing apparatus 102 removes unnecessary portions of the shaped object 15 after additive manufacturing by rotating the tool 19 with the spindle drive device 22. The subtractive manufacturing apparatus 102 moves the processing head 21 relative to the workpiece 16 to move the tip position of the tool 19 relative to the workpiece 16. The subtractive manufacturing apparatus 102 may move the tip position of the tool 19 relative to the workpiece 16 by moving the workpiece 16 relative to the processing head 21. The subtractive manufacturing apparatus 102 may also rotate the workpiece 16 instead of the tool 19. When the subtractive manufacturing apparatus 102 rotates the tool 19, the rotation axis of the tool 19 becomes the main axis, and when the subtractive manufacturing apparatus 102 rotates the workpiece 16, the rotation axis of the workpiece 16 becomes the main axis.

[0032] The NC device 1 controls the removal manufacturing device 102 in accordance with the machining program. The NC device 1 controls the position of the machining head 21 driven by the head driving device 20 by outputting a position command to the head driving device 20. The NC device 1 controls the tool rotational speed by outputting an output command, which is a command according to the conditions of the tool rotational speed (spindle rotational speed) set in the machining program, to the spindle driving device 22. The tool rotational speed is the number of rotations of the tool 19 per unit time.

[0033] The NC device 1 may be one of the components of the removal manufacturing apparatus 102, or may be an external device to the removal manufacturing apparatus 102.

[0034] In addition, in embodiment 1, the additive manufacturing apparatus 100 and the subtractive manufacturing apparatus 102 are described as different components, but the additive manufacturing apparatus 100 and the subtractive manufacturing apparatus 102 may be a composite manufacturing apparatus having both additive manufacturing functions and subtractive manufacturing functions.

[0035] 2 is a diagram showing a functional configuration of the NC device according to the embodiment 1. The NC device 1 includes an additive manufacturing execution unit 103, a state analysis unit 104, a production process change unit 105, a process condition generation unit 106, and a subtractive manufacturing execution unit 107.

[0036] The additive manufacturing execution unit 103 accepts an externally input processing program 23. The processing program 23 is a program used when manufacturing a shaped object 15 by melting a material 5 with a beam emitted from the processing head 8 and adding the melted material 5 to a workpiece 16.

[0037] The machining program 23 describes movement commands and speed commands required to move the workpiece 16 or the machining head 8 along a preset path, laser beam output commands required to perform additive manufacturing at a desired stacking height and stacking width, and metal powder or metal wire supply commands. The stacking height and stacking width are the stacking height and stacking width per layer. The movement commands are represented by movement command values, and the speed commands are represented by speed command values. The output commands are represented by output command values, and the supply commands are represented by supply amount command values. In the following description, the supply of metal powder or metal wire may be referred to as metal supply.

[0038] The movement command and speed command in the additive manufacturing execution unit 103 are commands that specify the relative position and relative speed between the workpiece 16 and the processing head 8. Therefore, the position and speed of the processing head 8 in the additive manufacturing execution unit 103 are the relative position and relative speed between the workpiece 16 and the processing head 8. In the following explanation, a case where the processing head 8 is controlled when controlling the relative position and relative speed between the workpiece 16 and the processing head 8 will be explained.

[0039] In addition, the additive manufacturing execution unit 103 receives a production process switching command from the production process change unit 105. The production process switching command is a switching command from an additive manufacturing process (additive processing process) to a subtractive manufacturing process (removal processing process), or a switching command from a subtractive manufacturing process to an additive manufacturing process.

[0040] The additive manufacturing execution unit 103 controls the movement path of the head position of the processing head 8 (hereinafter referred to as head movement path HR8), and the output value of the laser beam and the supply amount of material 5 (metal supply amount) on the head movement path HR8 based on the processing program 23. The head movement path HR8 is the processing path by the processing head 8. In this way, the additive manufacturing execution unit 103 causes the additive manufacturing apparatus 100 to additively manufacture the shaped object 15.

[0041] When the additive manufacturing execution unit 103 receives a command to switch from the additive manufacturing process to the subtractive manufacturing process, it stops additive manufacturing. When the additive manufacturing execution unit 103 receives a command to switch from the subtractive manufacturing process to the additive manufacturing process, it resumes additive manufacturing.

[0042] The state analysis unit 104 receives the sensor data 24 acquired from the additive manufacturing apparatus 100. The state analysis unit 104 analyzes the machining state of the object 15 based on the sensor data 24. The sensor data 24 includes image data, temperature data, and molten pool data, which will be described later.

[0043] The state analysis unit 104 sends the processing state, which is the analysis result, to the production process change unit 105 and the process condition generation unit 106. The processing state that the state analysis unit 104 sends to the process condition generation unit 106 includes a determination result as to whether stable modeling processing can be continued or not.

[0044] The sensor data 24 acquired from the additive manufacturing apparatus 100 may be stored in a storage device or the like. In this case, the storage device may be disposed within the NC apparatus 1 or may be disposed outside the NC apparatus 1. In addition, the storage device may be disposed within the additive manufacturing apparatus 100 or may be disposed outside the additive manufacturing apparatus 100.

[0045] The production process change unit 105 automatically changes between the additive manufacturing process and the subtractive manufacturing process depending on the processing state of the model 15. When the state analysis unit 104 determines that stable modeling processing cannot be continued, the production process change unit 105 changes from the additive manufacturing process to the subtractive manufacturing process. In addition, when the production process change unit 105 receives a notification from the subtractive manufacturing execution unit 107 indicating that the subtractive manufacturing process has been completed, the production process change unit 105 changes from the subtractive manufacturing process to the additive manufacturing process.

[0046] The production process change unit 105 sends a switch command from an additive manufacturing process to a subtractive manufacturing process, and a switch command from a subtractive manufacturing process to an additive manufacturing process, to the additive manufacturing execution unit 103. In addition, the production process change unit 105 sends a switch command from an additive manufacturing process to a subtractive manufacturing process to the subtractive manufacturing execution unit 107. In addition, when sending a switch command to the additive manufacturing execution unit 103 or the subtractive manufacturing execution unit 107, the production process change unit 105 sends a transport command for the shaped object 15 to the automatic transport device 101.

[0047] The process condition generation unit 106 receives the processing state from the state analysis unit 104. When the state analysis unit 104 determines that stable continuation of modeling processing is impossible, the process condition generation unit 106 calculates the process conditions to be used by the subtractive manufacturing apparatus 102 after the production process change. In this case, the process condition generation unit 106 calculates the process conditions to be used by the subtractive manufacturing apparatus 102 after the production process change based on the process conditions and processing state used by the additive manufacturing apparatus 100 before the production process change.

[0048] The process conditions used before the change in the production process include the head movement path HR8 and the like. The process condition generation unit 106 may acquire the process conditions used before the change in the production process from the additive manufacturing execution unit 103, or may calculate them from the machining program 23. The process condition generation unit 106 sends the calculated process conditions to the subtractive manufacturing execution unit 107. The process conditions calculated by the process condition generation unit 106 include the movement path of the head position of the machining head 21 (hereinafter referred to as the head movement path HR21) and the like. The head movement path HR21 is the machining path by the machining head 21.

[0049] The removal manufacturing execution unit 107 receives a production process switching command from the production process change unit 105. The removal manufacturing execution unit 107 also receives process conditions from the process condition generation unit 106. The removal manufacturing execution unit 107 controls the head movement path HR21 and the tool rotation speed on the head movement path HR21 based on the process conditions received from the process condition generation unit 106. In this way, the removal manufacturing execution unit 107 causes the removal manufacturing apparatus 102 to remove and manufacture a part of the shaped object 15.

[0050] The movement command and speed command in the removal manufacturing execution unit 107 are commands that specify the relative position and relative speed between the workpiece 16 and the processing head 21. Therefore, the position and speed of the processing head 21 in the removal manufacturing execution unit 107 are the relative position and relative speed between the workpiece 16 and the processing head 21. In the following description, a case where the processing head 21 is controlled when controlling the relative position and relative speed between the workpiece 16 and the processing head 21 will be described.

[0051] Next, a description will be given of an example of the operation of the NC device 1. Fig. 3 is a flowchart showing the procedure of the operation of the NC device according to the first embodiment.

[0052] (Step S10) In step S10, the processing program 23 is externally input to the additive manufacturing execution unit 103. As a result, the additive manufacturing execution unit 103 accepts the processing program 23. As described above, the processing program 23 includes a laser beam output command and a metal powder or metal wire supply command. The processing program 23 also includes a movement command for controlling the relative position between the workpiece 16 and the processing head 8, and a speed command for controlling the relative speed between the workpiece 16 and the processing head 8. The speed command for the processing head 8 is a scanning speed command at the laser irradiation position.

[0053] In the movement command for the machining head 8, the contents of the movement command are specified by coordinate values ​​and a G code (e.g., G0, G1, etc.) that indicates the movement mode at the coordinate values. In addition, in the speed command for the machining head 8, the contents of the speed command are specified by an F code in which a speed value is described.

[0054] To perform additive manufacturing, the desired stacking height and stacking width set by the user, the output command value of the laser beam at this time, and the supply amount command value of the metal powder or metal wire at this time are required. In other words, to perform additive manufacturing, the output command value of the laser beam and the supply amount command value of the metal supply corresponding to the desired stacking height and stacking width are required. The additive manufacturing device 100 receives the stacking height and stacking width, the output value of the laser beam, the metal supply amount, and the processing head 8's scanning At least one piece of information associated with the speed (movement speed) is stored as a lump of data. Such lump of data will be referred to as stacking condition data below. In the first embodiment, the X-axis direction is the stacking width, and the Z-axis direction is the stacking height.

[0055] In the processing program 23, the laser beam output command value and the metal supply amount command value are set using the G code or M code based on the lamination condition data so as to obtain the desired lamination height and lamination width. That is, in the processing program 23, the information included in the lamination condition data is set using the G code, M code, etc.

[0056] In order to obtain the desired stack height and stack width, the laser beam output command value and the metal supply amount command value may be directly written on the machining program 23. After executing step S10, the NC device 1 advances the procedure to step S20.

[0057] (Step S20) In step S20, the additive manufacturing execution unit 103 analyzes the movement path for moving the processing head 8 in the additive manufacturing device 100 based on the contents of the processing described in the externally input processing program 23, and determines the movement path. The additive manufacturing execution unit 103 also determines the scanning speed, which is the movement speed of the processing head 8, based on the processing program 23. The additive manufacturing execution unit 103 also determines the laser output value and metal supply amount required for the additive manufacturing process based on the processing program 23. Then, the additive manufacturing execution unit 103 causes the additive manufacturing device 100 to perform additive manufacturing using the determined movement path, scanning speed, laser output value, and metal supply amount. After executing step S20, the NC device 1 advances the procedure to step S30.

[0058] (Step S30) In step S30, the sensor data 24 for monitoring the processing state of the additive manufacturing apparatus 100 is collected from the additive manufacturing apparatus 100 and input to the state analysis unit 104. As a result, the state analysis unit 104 acquires the sensor data 24.

[0059] The sensor data 24, which is the sensor information, includes, for example, image data for measuring (analyzing) the actual stack height and stack width, temperature data for measuring (analyzing) the heat storage state of the molded object 15, and molten pool data for measuring (analyzing) the welding state of the metal powder or metal wire. The image data is data showing an image of the molded object 15, and is acquired using at least one of a camera and a laser displacement meter. The temperature data is data showing the temperature of the molded object 15, and is acquired using at least one of a radiation thermometer and an infrared thermograph. The molten pool data is data showing information on the molten pool, and is acquired using at least one of a camera and a motor detector provided in the material supply device 4. The motor detector provided in the material supply device 4 is a device that detects the load torque applied to the material supply device 4. Therefore, the molten pool data is acquired using at least one of the data of the image captured by the camera and the load torque detected by the motor detector.

[0060] In addition, there are three types of deposition states of the metal powder or metal wire: a deposition amount shortage state, a deposition amount stable state, and a deposition amount excess state. Figure 4 is a diagram for explaining the deposition state during modeling by the additive manufacturing device shown in Figure 1.

[0061] 4 shows examples of bead shapes for each of three welding states, namely, an insufficient welding amount state, a stable welding amount state, and an excessive welding amount state. The bead shape is a three-dimensional shape of one layer of the shaped object 15.

[0062] The top part of Fig. 4 shows the bead shape when the stacked shapes of the three welded states are viewed from the Y direction, which is the scanning direction of the laser beam, while the bottom part of Fig. 4 shows the bead shape when the stacked shapes of the three welded states are viewed from the Z direction, which is the irradiation direction of the laser beam.

[0063] In Fig. 4, the insufficient deposition amount state is a state in which the deposition amount is insufficient, so that only partial deposition is performed and a layer with the desired shape is not formed. The stable deposition amount state is a state in which the deposition amount is appropriate and a layer with the desired shape is formed. The excessive deposition amount state is a state in which the deposition amount is too large, so that the welded material 5 flows and a layer with the desired shape is not formed. In the excessive deposition amount state, the shape is flatter than the desired shape.

[0064] The width of the layer of the shape in the insufficient deposition amount state is smaller than the width of the layer of the shape in the stable deposition amount state, and the height of the shape in the insufficient deposition amount state is greater than the height of the shape in the stable deposition amount state.

[0065] The width of the shape in the excessive deposition state is larger than the width of the shape in the stable deposition state. Also, the height of the shape in the excessive deposition state is smaller than the height of the shape in the stable deposition state. After executing step S30, the NC device 1 proceeds to step S40.

[0066] (Step S40) In step S40, the state analysis unit 104 determines whether additive modeling (additive manufacturing) is possible stably based on the image data, temperature data, and molten pool data included in the sensor data 24. That is, the state analysis unit 104 determines whether the additive manufacturing process in the additive manufacturing apparatus 100 can be continued stably.

[0067] The image data included in the sensor data 24 is data indicating whether the additively manufactured bead has a uniform height and width without variation and can be additively manufactured without error. The temperature data included in the sensor data 24 is data indicating whether the time required for solidification of the molten material is increasing due to the heat storage temperature of the molded object 15. The molten pool data included in the sensor data 24 is data indicating whether the deposition state of the metal powder or metal wire can maintain a stable deposition amount.

[0068] The condition analysis unit 104 performs a prior analysis based on image data and temperature data to determine whether the time required for the molten material to solidify will increase due to the effect of heat accumulation and whether distortion or collapse will occur around the processed portion of the object 15 due to the effect of gravity.

[0069] The condition analysis unit 104 performs a prior analysis based on the image data and the molten pool data to determine whether distortion or collapse will occur around the processed portion of the object 15 due to the welding condition falling outside the range of appropriate process conditions and the inability to form the desired bead shape.

[0070] If the state analysis unit 104 of the NC device 1 determines that the stable state of the deposition amount can be maintained, that is, if it determines that stable additive modeling is possible (Yes in Step S40), the state analysis unit 104 proceeds to Step S30.

[0071] On the other hand, when the state analyzing unit 104 determines that the stable state of the deposition amount cannot be maintained, that is, when it determines that stable additive modeling is impossible (Step S40, No), the state analyzing unit 104 proceeds to the procedure of Step S50.

[0072] (Step S50) In step S50, the state analysis unit 104 notifies the production process change unit 105 and the process condition generation unit 106 that stable modeling processing cannot be continued. As a result, the production process change unit 105 interrupts additive manufacturing and changes the process to subtractive manufacturing, that is, executes a production process switching operation. In this case, the additive manufacturing process is the first production process, and the subtractive manufacturing process is the second production process. Also, the process conditions used in the additive manufacturing process are the first process conditions, and the process conditions used in the subtractive manufacturing process are the second process conditions.

[0073] The switching operation of the production process includes an operation in which the production process change unit 105 transmits an interruption signal (switching command) of the additive manufacturing process to the additive manufacturing execution unit 103 to temporarily interrupt the additive manufacturing process. The switching operation of the production process also includes an operation in which the production process change unit 105 causes the automatic conveying device 101 to execute a transport operation of the shaped object 15 after the interruption of the additive manufacturing process is completed. In the transport operation of the shaped object 15 here, the production process change unit 105 causes the automatic conveying device 101 to take out the shaped object 15 from the additive manufacturing device 100 and set it on the stage 18 of the removal manufacturing device 102. The switching operation of the production process also includes an operation in which the production process change unit 105 transmits a start signal (switching command) of the removal manufacturing process to the removal manufacturing execution unit 107 to prepare for the removal manufacturing process. In this way, the production process change unit 105 transmits a switching command from the additive manufacturing process to the removal manufacturing execution unit 103 and the removal manufacturing execution unit 107.

[0074] In addition, when the additive manufacturing apparatus 100 and the subtractive manufacturing apparatus 102 are composite manufacturing apparatuses having both additive manufacturing functions and subtractive manufacturing functions, the switching process between the additive manufacturing execution unit 103 and the subtractive manufacturing execution unit 107 in the switching operation of the production process is synonymous with the replacement process of the machining heads 8 and 21. In other words, when the additive manufacturing apparatus 100 and the subtractive manufacturing apparatus 102 are composite manufacturing apparatuses, the production process change unit 105 outputs a replacement command (replacement signal) for the machining heads 8 and 21 instead of a switching command. After executing step S50, the NC device 1 proceeds to step S60.

[0075] (Step S60) In step S60, the process condition generating unit 106 generates process conditions to be used in the removal manufacturing process by the removal manufacturing execution unit 107. Specifically, the process condition generating unit 106 determines the movement path and scanning speed of the processing head 21 in the removal manufacturing apparatus 102, and the tool rotation speed of the processing head 21, and sets them as the process conditions for the removal manufacturing process.

[0076] The process condition generating unit 106 sets the head movement path HR21 in the removal manufacturing apparatus 102 based on the processing program 23 input to the additive manufacturing apparatus 100. Specifically, the process condition generating unit 106 extracts the head movement path HR21 so that all the locations where the shape around the processed part may be distorted or collapsed due to the influence of the heat storage temperature and the welding state of the shaped object 15 can be removed. In this case, the process condition generating unit 106 extracts the head movement path HR21 in the removal manufacturing process so that the processing program 23 is offset in three-dimensional space from the command location where the additive manufacturing apparatus 100 temporarily suspended the processing and traces it back. In other words, the process condition generating unit 106 sets the head movement path HR21 in the removal manufacturing process so that the head movement path HR8 set in the processing program 23 is given an offset portion and traced in the reverse direction from the position where the additive manufacturing apparatus 100 suspended the additive manufacturing. This makes it easy to set the start point and end point of the processing head 21 in the removal manufacturing process. Moreover, it becomes easier to set the starting point of the processing head 8 in the subsequent additional process.

[0077] Moreover, the process condition generating unit 106 sets the scanning speed of the machining head 21, which is set in the machining program (machining program 33 described later) used in the removal manufacturing apparatus 102, as the process condition of the removal manufacturing process. Moreover, the process condition generating unit 106 determines the tool rotation speed of the machining head 21 on the head movement path HR21 based on the maximum value of the removal amount in the removal manufacturing execution unit 107. That is, the process condition generating unit 106 sets the tool rotation speed that can remove a desired amount for a portion of the head movement path HR21 where the removal amount is the largest. The process condition generating unit 106 sends the head movement path HR21 and the tool rotation speed on the head movement path HR21 to the removal manufacturing execution unit 107. After executing step S60, the NC device 1 advances the procedure to step S70.

[0078] (Step S70) In step S70, the removal manufacturing execution unit 107 receives the head movement path HR21, the scanning speed, and the tool rotation speed on the head movement path HR21 generated by the process condition generation unit 106. In this way, the removal manufacturing execution unit 107 determines command values ​​for the movement path of the processing head 21, the scanning speed, and the tool rotation speed required for removal manufacturing to be output to the removal manufacturing device 102. The removal manufacturing execution unit 107 causes the removal manufacturing device 102 to start removal manufacturing using the determined movement path, scanning speed, and tool rotation speed. After executing step S70, the NC device 1 advances the procedure to step S80.

[0079] (Step S80) In step S80, after the removal manufacturing execution unit 107 completes the removal manufacturing, the production process change unit 105 executes a return operation of the production process. The return operation of the production process includes an operation in which the production process change unit 105 receives a completion notification of the removal manufacturing from the removal manufacturing execution unit 107. The return operation of the production process also includes an operation in which the production process change unit 105 causes the automatic conveyance device 101 to execute a transport operation of the shaped object 15. In the transport operation of the shaped object 15 here, the production process change unit 105 causes the automatic conveyance device 101 to take out the shaped object 15 from the removal manufacturing device 102 and set it on the stage 13 of the additive manufacturing device 100. The return operation of the production process also includes an operation in which the production process change unit 105 transmits a start signal (switching command) of the additive manufacturing process to the additive manufacturing execution unit 103 to prepare for the additive manufacturing process. After executing step S80, the NC device 1 advances the procedure to step S90.

[0080] (Step S90) In step S90, the additive manufacturing execution unit 103 causes the additive manufacturing apparatus 100 to resume additive manufacturing. That is, the additive manufacturing execution unit 103 resumes the analysis of the head movement path HR8 for moving the processing head 8 from the end position of the removal manufacturing in the removal manufacturing execution unit 107 based on the contents of the processing described in the processing program 23, and determines the head movement path HR8 and the scanning speed. In addition, the additive manufacturing execution unit 103 determines the laser output value and metal supply amount required for the additive manufacturing process based on the processing program 23. Then, the additive manufacturing execution unit 103 causes the additive manufacturing apparatus 100 to resume additive manufacturing using the determined movement path, scanning speed, laser output value, and metal supply amount. After executing step S90, the NC device 1 advances the procedure to step S100.

[0081] (Step S100) In step S100, the NC device 1 determines whether or not all of the processes described in the machining program 23 have been completed. If all of the processes described in the machining program 23 have not been completed (step S100, No), the NC device 1 repeats the processes from steps S30 to S100. The NC device 1 repeats the processes from steps S30 to S100 until all of the processes described in the machining program 23 have been completed. If all of the processes described in the machining program 23 have been completed (step S100, Yes), the NC device 1 completes the process of controlling the manufacture of the object 15.

[0082] In this way, the NC device 1 can detect in advance distortion or collapse of the finished object 15 caused by changes in the heat storage state or welding state during the additive manufacturing process, and switch from the additive manufacturing process to the subtractive manufacturing process. This makes it possible for the NC device 1 to efficiently and accurately produce the object 15 having the desired shape without interrupting the production process.

[0083] Here, an example of the machining program 23 will be described. Fig. 5 is a diagram showing an example of a machining program used by the NC device according to the first embodiment. The machining program 23 prescribes issuing a command using an absolute value command, executing tool length compensation with the H1th compensation amount (H1 is a natural number), and determining the scanning speed, laser output value, and metal supply amount. In the NC device 1, a plurality of compensation amounts are set as the compensation amount for tool length compensation. In the machining program 23, it is set which compensation amount among these plurality of compensation amounts is to be used.

[0084] In addition, in the machining program 23, a coordinate value group for the first layer of the shaped object 15, a coordinate value group for the second to (N-1)th layers, a coordinate value group for the Nth layer, etc. are set. In the following, a case where the shaped object 15 has an arc shape when viewed from the Z-axis direction will be described. When the shaped object 15 has an arc shape when viewed from the Z-axis direction, coordinate value groups for the first to Nth layers of the arc shape are set in the machining program 23. The machining program 23 is input to the additive manufacturing execution unit 103 from outside the NC device 1.

[0085] Fig. 6 is a diagram showing an example of a model that is additively manufactured by the additive manufacturing apparatus using the processing program shown in Fig. 5 by the NC apparatus according to the first embodiment. The model 50 shown in Fig. 6 is an example of the model 15 manufactured by the additive manufacturing apparatus 100.

[0086] The additive manufacturing apparatus 100 heats and melts the material 5, which is a metallic material such as metal powder or metal wire, supplied onto the base material 14 using a laser beam, and layers the material 5 on the processed portion of the base material surface at a specified layer height and layer width.

[0087] The additive manufacturing apparatus 100 repeats the process of moving the processing head 8 to stack the material 5 so that the laser irradiation area on the base material has an arc shape when viewed from the Z-axis direction. Such N layers of material 5 stacked in the Z-axis direction (N is a natural number) are the object 50 shown in FIG.

[0088] In the first embodiment, N included in the machining program 23 shown in FIG. 1 (N 1 A case will be described in which, during a command for the additive manufacturing process of the 1st layer (where N is a natural number from 1 to N), the shape of the object 50 is distorted or collapsed due to an increase in heat accumulation on the surface of the object 50 or an instability in the welding state. The operation of each component of the NC device 1 in this case will be described in detail below.

[0089] (Additive Manufacturing Execution Unit 103) The additive manufacturing execution unit 103 of the NC device 1 analyzes the machining program 23 and performs additive manufacturing using the additive manufacturing device 100. The additive manufacturing execution unit 103 analyzes the processing to be performed after the currently performed processing in the machining program 23 shown in FIG.

[0090] The additive manufacturing execution unit 103 analyzes the movement path and scanning speed Fc(t) of the machining head 8 described in the machining program 23 to determine the position of the machining head 8 per unit time. Specifically, the additive manufacturing execution unit 103 determines the position of the machining head 8 by performing an acceleration / deceleration process that generates a speed waveform for accelerating and decelerating at a preset acceleration, and a smoothing process that smoothes the speed waveform generated by the acceleration / deceleration process. The smoothing process is also called a moving average filter process.

[0091] Furthermore, the additive manufacturing execution unit 103 generates a command position for the machining head 8 by performing an interpolation process to calculate an interpolation point, which is the machining head position per unit time when moving at the scanning speed after the smoothing process. The additive manufacturing execution unit 103 outputs this command position to the head driving device 12 per unit time. As a result, the machining head 8 is controlled to the desired position set in the machining program 23.

[0092] In addition, the additive manufacturing execution unit 103 analyzes the supply speed of the material 5 and the intensity of the laser beam described in the processing program 23, and determines the supply speed of the material 5 per unit time and the intensity of the laser beam.

[0093] The additive manufacturing execution unit 103 adjusts the laser output value Pc(t) and the metal supply amount Wc(t) at the laser irradiation position according to the scanning speed Fc(t) of the laser irradiation position using the following equations (1) and (2).

[0094]

number

[0095]

number

[0096] Here, P, V, and F respectively represent the laser output, metal supply amount, and scanning speed described in the processing program 23. The additive manufacturing execution unit 103 outputs a laser output value Pc(t) corresponding to the scanning speed of the laser irradiation position to the laser oscillator 2. The additive manufacturing execution unit 103 also outputs a metal supply amount Wc(t) of metal powder or metal wire to the material supply device 4. In this way, the additive manufacturing execution unit 103 controls the laser output and metal supply amount to values ​​desired by the user specified in the processing program 23. Note that the program analysis process from the 1st layer to the Nth layer by the additive manufacturing execution unit 103 and the analysis process by the state analysis unit 104 are performed simultaneously.

[0097] When the additive manufacturing process is resumed, the additive manufacturing execution unit 103 analyzes the movement path and scanning speed Fc(t) of the machining head 8 described in the machining program 23 from the end position of the subtractive manufacturing process, and determines the machining head position per unit time.

[0098] (Status analysis unit 104) The state analysis unit 104 of the NC device 1 collects sensor data 24 from a sensor installed in the additive manufacturing device 100, and estimates the state during additive manufacturing based on the sensor data 24. Specifically, the state analysis unit 104 acquires image data of the modeled shape formed by the additive manufacturing device 100 from the sensor data 24. Furthermore, the state analysis unit 104 extracts feature amounts of the modeled shape from the image data of the modeled shape formed by the additive manufacturing device 100. The feature amounts of the modeled shape extracted here include at least one of the stacking height and stacking width. The state analysis unit 104 calculates the feature amounts including at least one of the stacking height and stacking width using an image analysis method such as edge detection and binarization.

[0099] The state analysis unit 104 acquires temperature data obtained by observing the surface temperature of the processed part in the additive manufacturing process. InfraredThe heat map may be a heat map in which the processed part obtained by thermography is displayed in different colors according to the surface temperature, or may be data in which the surface temperature is described as a numerical value according to the coordinate position of the shaped object 15. Furthermore, the state analysis unit 104 may obtain a heat map detected from multiple directions using multiple sensors.

[0100] Furthermore, the state analysis unit 104 acquires molten pool data obtained by observing the molten pool formed by the additive manufacturing apparatus 100. The state analysis unit 104 acquires the molten pool data by extracting shape feature values ​​from image data obtained by measuring the molten pool. The shape feature values ​​extracted here include at least one of the molten pool size and the distance from the center of the molten pool to the material 5. The state analysis unit 104 calculates the feature values ​​including at least one of the molten pool size and the distance from the center of the molten pool to the material 5 using an image analysis method such as edge detection or binarization.

[0101] Furthermore, the condition analysis unit 104 is not limited to directly observing the molten pool from image data, and may estimate the molten state by utilizing load data (load torque) applied to the material supply device 4, etc. Based on the image data, temperature data, and molten pool data, the condition analysis unit 104 analyzes in advance whether distortion or collapse will occur around the processed part of the object 15 due to changes in the heat accumulation state and welding state.

[0102] Here, the relationship between the temperature data and the change in the bead width will be described. Also, the relationship between the molten pool data and the change in the bead height will be described. The bead width and the bead height are examples of shape states that indicate the shape of the molded object 15.

[0103] FIG. 7 is a diagram for explaining the relationship between the temperature data of the processed part extracted as a feature amount during the additive manufacturing process by the NC device according to the first embodiment and the change in bead width.

[0104] In FIG. 7, when the model 50 is manufactured, a model 51A in which up to the tenth layer is laminated and N 1 The figure shows a shaped object 51B in which the layers are stacked up to the Nth layer. 1is a natural number greater than 10. As shown in FIG. 7, the desired stacking is performed in the model 51A in which the tenth layer has been stacked. 1 In the model 51B in which layers have been stacked up to the th layer, the desired stacking has not been performed.

[0105] As the additive manufacturing time passes, heat accumulation in the model 51B increases due to the effect of the laser beam continuing to irradiate the base material. As a result, the time required for solidification of the molten material changes, and the stacking width becomes larger than the desired value due to the effect of gravity of the molten material, and the stacking height becomes smaller than the desired value, making it easier for the shape to collapse. In other words, when heat accumulation in the model 51B increases, the time required for solidification of the molten material becomes longer, and the molten material spreads too much. For this reason, the state analysis unit 104 detects in advance that the time required for solidification of the molten material increases due to the effect of heat accumulation, and distortion or collapse occurs around the processed part of the model 51B due to the effect of gravity. The state analysis unit 104 generates a modeling abnormality signal when the heat accumulation of the temperature data in the processed part is greater than the heat accumulation threshold and the stacking width is greater than the stacking width threshold.

[0106] FIG. 8 is a diagram for explaining the relationship between the molten pool data of the processed part extracted as a feature during the additive manufacturing process by the NC device according to the first embodiment and the change in bead height.

[0107] In FIG. 8, when the shaped object 50 is manufactured, a shaped object 51A in which up to the tenth layer is laminated and N 2 The figure shows a model 51C in which the layers are stacked up to the Nth layer. 2 is a natural number greater than 10. As shown in FIG. 8, the desired stacking is performed in the model 51A in which the tenth layer has been stacked. 2 In the model 51C in which layers have been stacked up to the th layer, the desired stacking has not been performed.

[0108] Even if the melting amount of material 5 is optimally commanded for the laser beam at the start of the additive manufacturing process, as the additive manufacturing process time passes, the material 5 becomes more likely to melt due to the heat source of the laser beam, and the distance between the supplied material 5 and the molten pool formed by the molten material 5 increases. This causes the size of the molten pool to become smaller, resulting in a shortage of the amount of welding, the stacking width to become smaller than the desired value, and the stacking height to become higher than the desired value. Furthermore, the variation in the stacking width and stacking height increases. This makes it easier for the shape to collapse. For this reason, if the additive manufacturing process time becomes longer, the welding state falls outside the optimal condition range, making it impossible to form the desired bead shape, and distortion or collapse occurs around the processed part of the model 51C. The state analysis unit 104 Like this The state analysis unit 104 detects in advance any distortion or collapse around the workpiece. When the molten pool size of the molten pool data in the workpiece is smaller than a molten pool size threshold and the stacking height is larger than a stacking height threshold, the state analysis unit 104 generates a printing abnormality signal.

[0109] In the first embodiment, N in the middle of the machining program 23 1 The heat accumulation in the layers can cause distortion or collapse of the shape, resulting in N 2 In the layer, the shape is distorted or broken due to the influence of the welding state. Therefore, the state analysis unit 104 analyzes the sensor data 24 to detect the shape abnormality signal N before the distortion or breakage occurs. 1 Layer or N 2 Although the printing abnormality signal is generated only once for the layer, the printing abnormality signal may be generated multiple times each time the occurrence of distortion or collapse is detected.

[0110] (Production Process Change Department 105) The production process change unit 105 of the NC device 1 automatically changes between the additive manufacturing process and the subtractive manufacturing process based on the analysis result of the machining state by the state analysis unit 104. In the first embodiment, in the machining program 23, 1 -1) Since the state analysis unit 104 does not generate a printing abnormality signal up to the layer 1, the production process change unit 105 continues the additive manufacturing process in the additive manufacturing apparatus 100. On the other hand, in the processing program 23,1 When it comes to the layer, the production process change unit 105 receives a printing abnormality signal from the state analysis unit 104, and executes an operation of changing the production process.

[0111] The production process change unit 105 temporarily suspends the additive manufacturing process by transmitting an interruption signal for the additive manufacturing process to the additive manufacturing execution unit 103 as a production process change operation. When the additive manufacturing process by the additive manufacturing apparatus 100 is stopped, the production process change unit 105 transmits a conveyance start signal for the shaped object 15 to the automatic conveyance device 101 as a production process change operation. As a result, the automatic conveyance device 101 removes the shaped object 15 from the additive manufacturing apparatus 100 and sets it on the stage 18 of the removal manufacturing apparatus 102. When the automatic conveyance device 101 completes the process of setting the shaped object 15 on the stage 18 of the removal manufacturing apparatus 102, the production process change unit 105 transmits a start signal for the removal manufacturing process to the removal manufacturing apparatus 102. As a result, the removal manufacturing process is temporarily started.

[0112] When the removal manufacturing process is completed, the production process change unit 105 performs a return operation of the production process. The production process change unit 105 transmits a removal manufacturing stop signal to the removal manufacturing execution unit 107, Removal The manufacturing process is interrupted. Furthermore, when the removal manufacturing process by the removal manufacturing apparatus 102 is stopped, the production process change unit 105 transmits a signal to start transporting the model 15 to the automatic transport device 101 as a return operation of the production process. As a result, the automatic transport device 101 removes the model 15 from the removal manufacturing apparatus 102 and sets it on the stage 13 of the additive manufacturing apparatus 100. When the automatic transport device 101 completes the process of setting the model 15 on the stage 13 of the additive manufacturing apparatus 100, the production process change unit 105 transmits a signal to resume the additive manufacturing process to the additive manufacturing apparatus 100. As a result, the additive manufacturing process is resumed.

[0113] Here, the production process change unit 105 changes the N 1Although the case has been described where the production process change operation and the production process return operation are performed only once during the processing of a layer, the production process change unit 105 executes the production process change operation and the production process return operation each time a printing abnormality signal is input from the status analysis unit 104, as described in FIG. 3.

[0114] (Process condition generation unit 106) The process condition generation unit 106 of the NC device 1 determines the process conditions to be used by the subtractive manufacturing device 102 based on the machining program 23 used in the additive manufacturing device 100 and the machining state estimated by the state analysis unit 104.

[0115] The process condition generating unit 106 generates N in the removal manufacturing execution unit 107 based on the processing program 23 and the processing state. 1 A processing path for removing the layer, i.e., head movement path HR21, is generated. First, the N 1 The head movement path HR21 for removing the layer will now be described.

[0116] FIG. 9 is a diagram showing a first example of a head movement path in a removal manufacturing process that is generated by the NC device according to the first embodiment when the effect of heat accumulation occurs. In FIG. 9, a desired shape is shown by a shape 40DF, and N 1 The head movement path HR8, which is the processing path for additive manufacturing of the layer, is shown as additive manufacturing path 41A. 1 The actual stacking shape of the first layer is shown as stacking shape 41F. In addition, the N 1 The head movement path HR21, which is the processing path when removing a layer, is shown as a removal manufacturing path 46R1.

[0117] The process condition generating unit 106 is 1 Since the layer is the part where distortion or collapse occurs, N of the processing program 23 1 From the layer (N 1 -1) Extract the head movement path HR21 that is played back in reverse from the direction of travel so as to go back in time to the Nth layer. 1A head movement path HR21 that advances in the reverse direction along the layer additive manufacturing path 41A is extracted.

[0118] In addition, N formed by additive manufacturing processes 1 The width of the bead in the first layer is affected by heat accumulation. 1 The width is larger than the width of the bead formed before the layer. Therefore, the process condition generating unit 106 generates a removal manufacturing path 46R1 by offsetting the head movement path HR8 in the perpendicular direction, which is the direction perpendicular to the processing direction in a plane parallel to the XY plane, for the desired shape 40DF. The offset amount in this case is N 1 For the portion corresponding to the maximum value of the shape variation of the layer (the deviation amount from the desired value of the height or width of the model 15), a value exceeding the shape variation is set so that the tool 19 passes outside the layer shape 41F. 1 layer eye It is possible to remove all of the above, or only the portion that would cause distortion or loss of shape.

[0119] In addition, the removal manufacturing device 102 is N 1 If the bead of the layer cannot be removed in a single removal manufacturing path, the process condition generation unit 106 may generate multiple removal manufacturing paths by offsetting the extracted additive manufacturing path 41A multiple times.

[0120] 10 is a diagram showing a second example of a head movement path in the removal manufacturing process that is generated by the NC device according to the first embodiment when the effect of heat accumulation occurs. In FIG. 10, similarly to FIG. 9, the desired shape is indicated by a shape 40DF, and N 1 The head movement path HR8 for additive manufacturing of the layer is shown as additive manufacturing path 41A. 1 The actual stacking shape of the layers is shown as stacking shape 41F.

[0121] In addition, in Fig. 10, the N extracted when the effect of heat storage occurs 1The first head movement path HR21 when removing a layer is indicated by a removal manufacturing path 46R1, and the second head movement path HR21 is indicated by a removal manufacturing path 46R2. Note that the removal manufacturing apparatus 102 may first perform the removal manufacturing process along the removal manufacturing path 46R2, and then perform the removal manufacturing process along the removal manufacturing path 46R1.

[0122] Next, the N extracted when the deposition amount was insufficient was 1 Layer or N 2 The head movement path HR21 for removing the layer will be described. 1 Layer removal and N 2 Since the process for removing the first layer is similar, we will use N 1 The layer removal process will now be described.

[0123] 11 is a diagram showing a first example of a head movement path in the removal manufacturing process that is generated when the NC device according to the first embodiment is in a state of insufficient deposition amount. In FIG. 11, a desired shape is shown by a shape 40DF, and N 1 The head movement path HR8 for additive manufacturing of the layer is shown as additive manufacturing path 42A. 1 The actual layer shape of the layer is shown as layer shape 42F. In addition, N 1 The head movement path HR21 when removing a layer is shown as a removal manufacturing path 47R1.

[0124] The process condition generating unit 106 is 1 Since the layer is the part where distortion or collapse occurs, N of the processing program 23 1 From the layer (N 1 -1) Extract the head movement path HR21 reproduced in reverse from the direction of travel to the Nth layer. 1 A head movement path HR21 that advances in the reverse direction along the layer additive manufacturing path 42A is extracted.

[0125] In addition, N formed by additive manufacturing processes 1 The layer height of the bead of the first layer is affected by the insufficient welding condition.1 The height of the bead formed before the layer is larger than the height of the bead. Therefore, the process condition generating unit 106 generates a removal manufacturing path 47R1 by offsetting the head movement path HR8 in the Z-axis direction (depth direction) with respect to the desired shape 40DF. The offset amount in this case is N 1 The value is set to a value that exceeds the shape variation calculated from the maximum and minimum values ​​of the stacking height of the first layer. 1 layer eye It is possible to remove all of the above, or only the portion that would cause distortion or loss of shape.

[0126] In addition, the removal manufacturing device 102 is N 1 If the bead of the layer cannot be removed in a single removal manufacturing path, the process condition generation unit 106 may generate multiple removal manufacturing paths by offsetting the extracted additive manufacturing path 42A multiple times.

[0127] 12 is a diagram showing a second example of a head movement path in the removal manufacturing process that is generated when the NC device according to the first embodiment is in a state of insufficient deposition amount. In FIG. 12, similarly to FIG. 11, the desired shape is shown by shape 40DF, and N 1 Layer additive manufacturing head movement path HR8 is shown as additive manufacturing route 42A. 1 The actual stacking shape of the layers is shown as stacking shape 42F.

[0128] In addition, in Fig. 12, the N extracted when the deposition amount was insufficient 1 The first head movement path HR21 when removing a layer is indicated by a removal manufacturing path 47R1, and the second head movement path HR21 is indicated by a removal manufacturing path 47R2.

[0129] The process condition generating unit 106 also determines the tool rotation speed in the removal manufacturing device 102 in accordance with the removal amount of the shaped object 15. The bead shape of the shaped object 15 has non-uniform lamination width and lamination height due to the influence of the heat storage state and the welding state, and there is variation. For this reason, the process condition generating unit 106 derives the maximum removal volume in the head movement path HR21 (removal manufacturing paths 47R1, 47R2) used in the removal manufacturing device 102 based on the offset amount. Then, the process condition generating unit 106 determines the tool rotation speed optimal for the maximum removal volume and the scanning speed at this tool rotation speed based on the lamination condition data held by the NC device 1. That is, the process condition generating unit 106 determines the tool rotation speed and the scanning speed based on the volume at the point where the volume of the shaped object 15 removed in the removal manufacturing process is maximum in the removal manufacturing paths 47R1, 47R2, and the lamination conditions.

[0130] The process condition generating unit 106 may include a state quantity acquiring unit that acquires state quantities including the variation in the shape height or shape width of the object 15 after the first process is completed, the variation in the shape height or shape width of the object 15 after the second process is completed, and the offset amount of the tool path in the second process. The process condition generating unit 106 may include a learning unit that learns the offset amount of the tool path in the second process that reduces the variation in the shape height or shape width of the object 15 after the second process is completed, based on these state quantities.

[0131] (Removal Manufacturing Execution Unit 107) The removal manufacturing execution unit 107 of the NC device 1 analyzes the process conditions including the head movement path HR21 generated by the process condition generation unit 106, and causes the removal manufacturing device 102 to execute the removal manufacturing. The removal manufacturing execution unit 107 analyzes the head movement path HR21 generated by the process condition generation unit 106, regarding the processing to be performed after the processing currently being performed.

[0132] The removal manufacturing execution unit 107 analyzes the head movement path HR21 and the scanning speed in the removal manufacturing apparatus 102 generated by the process condition generation unit 106, and determines the processing head position of the processing head 21 per unit time. Specifically, the removal manufacturing execution unit 107 determines the processing head position of the processing head 21 by performing an acceleration / deceleration process for generating a speed waveform for accelerating and decelerating at a preset acceleration, and a smoothing process for smoothing the speed waveform generated by the acceleration / deceleration process.

[0133] Furthermore, the removal manufacturing execution unit 107 generates a command position for the machining head 21 by performing an interpolation process to calculate an interpolation point, which is the machining head position per unit time when moving at the scanning speed after the smoothing process. The removal manufacturing execution unit 107 outputs this command position to the head driving device 20 per unit time. This controls the machining head 21 to a desired position.

[0134] The removal manufacturing execution unit 107 analyzes the tool rotational speed generated by the process condition generation unit 106 and determines the tool rotational position per unit time. The head driving device 20 outputs the determined tool rotational position per unit time to a spindle control device (not shown), thereby controlling the tool rotational speed to a desired value.

[0135] Thus, according to the first embodiment, the NC device 1 detects in advance distortion or collapse of the object 15 caused by changes in the heat storage state or welding state during additive manufacturing, and switches from the additive manufacturing process to the subtractive manufacturing process. In this case, the NC device 1 creates process conditions including the head movement path HR21 used in the subtractive manufacturing process, based on the process conditions used in the additive manufacturing apparatus 100. This enables the NC device 1 to efficiently and accurately produce the object 15 in the desired shape without interrupting the production process.

[0136] In addition, the NC device 1 can also switch online between the additive manufacturing device 100 and the subtractive manufacturing device 102. This allows the NC device 1 to continue the production process before and after switching between the additive manufacturing process and the subtractive manufacturing process, enabling cooperation between processes and improving production efficiency.

[0137] Embodiment 2 Next, a second embodiment will be described with reference to Figures 13 to 15. In the second embodiment, the subtractive manufacturing device removes a part of the shaped object 15, and when there is a scratch or the like on the finished surface, the additive manufacturing device executes an additive manufacturing process.

[0138] The processing system 60 of the second embodiment includes an additive manufacturing apparatus 200 instead of the additive manufacturing apparatus 100, and a subtractive manufacturing apparatus 202 instead of the subtractive manufacturing apparatus 102. The processing system 60 of the second embodiment also includes an NC apparatus 1A instead of the NC apparatus 1. The processing system 60 of the second embodiment also includes an automatic transfer apparatus 101, similar to the processing system 60 of the first embodiment. The additive manufacturing apparatus 200 is an apparatus similar to the additive manufacturing apparatus 100, and the subtractive manufacturing apparatus 202 is an apparatus similar to the subtractive manufacturing apparatus 102.

[0139] Fig. 13 is a diagram showing the functional configuration of an NC device according to embodiment 2. Among the components shown in Fig. 13, those that achieve the same functions as those shown in Fig. 2 are given the same reference numerals, and duplicated explanations will be omitted.

[0140] The NC device 1A of the second embodiment includes an additive manufacturing execution unit 203, a status analysis unit 204, a production process change unit 205, a process condition generation unit 206, and a removal manufacturing execution unit 207. The additive manufacturing execution unit 203 executes processing corresponding to the processing executed by the additive manufacturing execution unit 103, and the status analysis unit 204 executes processing corresponding to the processing executed by the status analysis unit 104. The production process change unit 205 executes processing corresponding to the processing executed by the production process change unit 105, and the process condition generation unit 206 executes processing corresponding to the processing executed by the process condition generation unit 106. The removal manufacturing execution unit 207 executes processing corresponding to the processing executed by the removal manufacturing execution unit 107.

[0141] The removal manufacturing execution unit 207 receives an externally input processing program 33. The processing program 33 is a program used when forming the shaped object 15 into a desired shape by removing a part of the shaped object 15.

[0142] The machining program 33 describes movement commands and speed commands required to move the workpiece 16 or the machining head 21 along a preset path, and rotation commands for the tool rotation speed required to remove the desired surface roughness. The movement commands are expressed by movement command values, and the speed commands are expressed by speed command values. The rotation commands are expressed by rotation command values.

[0143] Furthermore, the removal manufacturing execution unit 207 receives a production process switching command from the production process change unit 205. The production process switching command is a command to switch from a removal manufacturing process to an additive manufacturing process, or a command to switch from an additive manufacturing process to a removal manufacturing process.

[0144] The removal manufacturing execution unit 207 controls the head movement path HR21 and the tool rotation speed on the head movement path HR21, based on the machining program 33. In this way, the removal manufacturing execution unit 207 causes the removal manufacturing apparatus 202 to remove and manufacture a part of the shaped object 15.

[0145] The subtractive manufacturing execution unit 207 stops subtractive manufacturing when it receives a command to switch from a subtractive manufacturing process to an additive manufacturing process. The additive manufacturing execution unit 203 resumes additive manufacturing when it receives a command to switch from a subtractive manufacturing process to an additive manufacturing process.

[0146] The state analysis unit 204 receives the sensor data 34 acquired from the removal manufacturing apparatus 202. The state analysis unit 204 analyzes the processing state of the object 15 based on the sensor data 34. The sensor data 34 includes image data, a load torque applied to the scanning axis of the processing head 21 detected by a motor detector included in the head driving device 20, and the like.

[0147] The state analysis unit 204 sends the processing state, which is the analysis result, to the production process change unit 205 and the process condition generation unit 206. The processing state that the state analysis unit 204 sends to the process condition generation unit 206 includes a determination result as to whether or not there is a scratch on the finished surface in the subtractive manufacturing process.

[0148] The sensor data 34 acquired from the removal manufacturing device 202 may be stored in a storage device or the like. In this case, the storage device may be a NC device. 1A It may be placed inside the NC device. 1A The storage device may be located within the additive manufacturing device 200 or may be located external to the additive manufacturing device 200.

[0149] Similar to the production process modification unit 105, the production process modification unit 205 automatically changes between a subtractive manufacturing process and an additive manufacturing process depending on the processing state of the shaped object 15. When the state analysis unit 204 determines that there is a scratch on the finished surface of the shaped object 15, the production process modification unit 205 changes from the subtractive manufacturing process to the additive manufacturing process. Furthermore, when the production process modification unit 205 receives a notification from the additive manufacturing execution unit 203 indicating that the additive manufacturing process has been completed, the production process modification unit 205 changes from the additive manufacturing process to the subtractive manufacturing process.

[0150] The production process change unit 205 sends a switch command from an additive manufacturing process to a subtractive manufacturing process, and a switch command from a subtractive manufacturing process to an additive manufacturing process, to the subtractive manufacturing execution unit 207. In addition, the production process change unit 205 sends a switch command from a subtractive manufacturing process to an additive manufacturing process to the additive manufacturing execution unit 203. In addition, when sending a switch command to the additive manufacturing execution unit 203 or the subtractive manufacturing execution unit 207, the production process change unit 205 sends a transport command for the shaped object 15 to the automatic transport device 101.

[0151] The process condition generation unit 206 receives the processing state from the state analysis unit 204. When the state analysis unit 204 determines that there is a scratch on the finished surface, the process condition generation unit 206 calculates the process conditions to be used by the additive manufacturing apparatus 200 after the production process change. In this case, the process condition generation unit 206 calculates the process conditions to be used by the additive manufacturing apparatus 200 after the production process change based on the process conditions and processing state used by the subtractive manufacturing apparatus 202 before the production process change.

[0152] The process conditions used before the change in the production process include the head movement path HR21, etc. The process condition generation unit 206 may acquire the process conditions used before the change in the production process from the subtractive manufacturing execution unit 207, or may calculate them from the machining program 33. The process condition generation unit 206 sends the calculated process conditions to the additive manufacturing execution unit 203. The process conditions calculated by the process condition generation unit 206 include the head movement path HR8, etc.

[0153] The additive manufacturing execution unit 203 receives a production process switching command from the production process change unit 205. The additive manufacturing execution unit 203 also receives process conditions from the process condition generation unit 206. The additive manufacturing execution unit 203 determines a head movement path based on the process conditions received from the process condition generation unit 206. HR8 and head movement path HR8 The additive manufacturing execution unit 203 controls the output value of the laser beam and the supply amount of the material 5 on the additive manufacturing apparatus 200. In this way, the additive manufacturing execution unit 203 causes the additive manufacturing apparatus 200 to additively manufacture the shaped object 15.

[0154] Next, an example of the operation of the NC device 1A will be described. Fig. 14 is a flowchart showing the procedure of the operation by the NC device according to the second embodiment. Note that the description of the same processes as those described in Fig. 3 will be omitted.

[0155] (Step S110) In step S110, the machining program 33 is externally input to the removal manufacturing execution unit 207. As a result, the removal manufacturing execution unit 207 accepts the machining program 33. As described above, the machining program 33 includes a movement command for controlling the relative position between the workpiece 16 and the machining head 21, and a speed command for controlling the relative speed between the workpiece 16 and the machining head 21. The speed command for the machining head 21 is a scanning speed command at the machining position by the tool 19.

[0156] In the movement command for the machining head 21, the contents of the movement command are specified by coordinate values ​​and a G code (e.g., G0, G1, etc.) that indicates the movement mode at the coordinate values. In addition, in the speed command for the machining head 21, the contents of the speed command are specified by an F code in which a speed value is described.

[0157] To perform subtractive manufacturing, a tool rotation speed command value based on a desired surface roughness set by a user is required. The tool rotation speed command value may be directly specified using an S code on the machining program 33 so as to obtain a desired surface roughness, or may be commanded using a G code or an M code. After executing step S110, the NC device 1A advances the procedure to step S120.

[0158] (Step S120) In step S120, the removal manufacturing execution unit 207 analyzes a movement path for moving the machining head 21 in the removal manufacturing device 202 based on the contents of the process described in the externally input machining program 33, and determines the movement path. The removal manufacturing execution unit 207 also determines a scanning speed, which is the movement speed of the machining head 21, based on the machining program 33. The removal manufacturing execution unit 207 also determines a tool rotation speed required for the removal manufacturing process based on the machining program 33. Then, the removal manufacturing execution unit 207 causes the removal manufacturing device 202 to perform removal manufacturing using the determined movement path, scanning speed, and tool rotation speed. After executing step S120, the NC device 1A advances the procedure to step S130.

[0159] (Step S130) In step S130, the sensor data 34 for monitoring the processing state of the removal manufacturing apparatus 202 is collected from the removal manufacturing apparatus 202 and input to the state analysis unit 204. As a result, the state analysis unit 204 acquires the sensor data 34.

[0160] The sensor data 34, which is the sensor information, includes, for example, image data for measuring (analyzing) the finish processing result. The image data is data showing an image of the shaped object 15, and is acquired using at least one of a camera and a laser displacement meter. The sensor data 34 may include load data applied to the head driving device 20 (load torque applied to the scanning axis of the processing head 21) and position data of the processing head 21, instead of image data for measuring the finish processing result. After executing step S130, the NC device 1A advances the procedure to step S140.

[0161] (Step S140) In step S140, the state analysis unit 204 detects scratches and the like caused by friction or mechanical vibrations that occur when the processing direction is switched, based on the image data included in the sensor data 34. That is, the state analysis unit 204 judges whether the removal manufacturing process in the removal manufacturing device 202 has been stably executed or not. The image data included in the sensor data 34 is data obtained by observing whether the modeling surface in the removal manufacturing process is free of variation and is being removed uniformly and without error.

[0162] When the condition analysis unit 204 of the NC device 1A determines that there is no damage on the finished surface of the shaped object 15 (Yes in step S140), the process proceeds to step S130.

[0163] On the other hand, if the condition analysis unit 204 determines that there is a scratch on the finished surface of the object 15 (No in step S140), the procedure proceeds to step S150. If the condition analysis unit 204 determines that there is a scratch on the finished surface of the object 15, the removal manufacturing execution unit 207 may cause the removal manufacturing apparatus 202 to perform removal manufacturing on the upper surface of the object 15 so as to remove the scratch.

[0164] The state analysis unit 204 can also estimate the friction or mechanical vibration that occurs when the processing direction is switched from the load data on the head drive device 20 and the position data of the processing head 21. In this case, the state analysis unit 204 indirectly calculates the finish processing result based on the load data on the head drive device 20 and the position data of the processing head 21. That is, the state analysis unit 204 calculates the friction or mechanical vibration based on the load data and the position data, and calculates the finish processing result (presence or absence of scratches, etc.) based on the friction or mechanical vibration. In this case, the state analysis unit 204 analyzes the presence or absence of scratches due to friction or mechanical vibration based on the friction or mechanical vibration that occurs when the processing direction is switched.

[0165] (Step S150) In step S150, the state analysis unit 204 notifies the production process change unit 205 and the process condition generation unit 206 that there is a scratch on the finishing surface of the shaped object 15. As a result, the production process change unit 205 interrupts the subtractive manufacturing and changes the process to additive manufacturing, that is, executes a production process switching operation. In this case, the subtractive manufacturing process is the first production process, and the additive manufacturing process is the second production process. Also, the process conditions used in the subtractive manufacturing process are the first process conditions, and the process conditions used in the additive manufacturing process are the second process conditions.

[0166] The production process switching operation includes an operation in which the production process change unit 205 transmits an interruption signal (switching command) of the removal manufacturing process to the removal manufacturing execution unit 207 to temporarily interrupt the removal manufacturing process. The production process switching operation also includes an operation in which the production process change unit 205 causes the automatic conveying device 101 to execute a transport operation of the shaped object 15 after the removal manufacturing process has been interrupted. In the transport operation of the shaped object 15 here, the production process change unit 205 causes the automatic conveying device 101 to take out the shaped object 15 from the removal manufacturing apparatus 202 and set it on the stage 13 of the additive manufacturing apparatus 200. The production process switching operation also includes an operation in which the production process change unit 205 transmits a start signal (switching command) of the additive manufacturing process to the additive manufacturing execution unit 203 to prepare for the additive manufacturing process. In this way, the production process change unit 205 transmits a switching command from the removal manufacturing process to the additive manufacturing execution unit 203 and the removal manufacturing execution unit 207. After executing step S150, the NC unit 1A advances the procedure to step S160.

[0167] (Step S160) In step S160, the process condition generation unit 206 generates process conditions to be used in the additive manufacturing process by the additive manufacturing execution unit 203. Specifically, the process condition generation unit 206 determines the movement path, scanning speed, laser output value, and metal supply amount of the processing head 8 in the additive manufacturing apparatus 200, and generates the process conditions of the additive manufacturing process. Regarding Set it up.

[0168] The process condition generating unit 206 sets the head movement path HR8 in the additive manufacturing device 200 based on the processing program 33 input to the subtractive manufacturing device 202. Specifically, the process condition generating unit 206 extracts the head movement path HR8 and sets it as the process condition of the additive manufacturing process so that all scratches caused by friction or mechanical vibrations that occur when the processing direction is switched can be removed. In this case, the process condition generating unit 206 extracts the head movement path HR8 in the additive manufacturing process so that the processing program 33 is offset in three-dimensional space from the command location where the subtractive manufacturing device 202 temporarily stopped and traced back. In other words, the process condition generating unit 206 sets the head movement path HR8 in the additive manufacturing process so that the head movement path HR21 set in the processing program 33 is given an offset portion and traced in the reverse direction from the position where the subtractive manufacturing device 202 interrupted the subtractive manufacturing.

[0169] In addition, the process condition generating unit 206 sets the scanning speed of the processing head 8 set in the processing program 33 used in the additive manufacturing device 200 as the process condition of the additive manufacturing process. In addition, the process condition generating unit 206 determines the command values ​​of the laser output value and the metal supply amount required for the additive manufacturing process so that all the generated scratches can be removed. In this case, the process condition generating unit 206 calculates the addition amount in the additive manufacturing execution unit 203 based on the volume of the scratches, the volume of the part removed to remove the scratches, and the like. Then, the process condition generating unit 206 determines the laser output value and the metal supply amount for the command path of the processing head position based on the addition amount in the additive manufacturing execution unit 203. The process condition generating unit 206 sends the head movement path HR8 and the laser output value and the metal supply amount on the head movement path HR8 to the additive manufacturing execution unit 203. After executing step S160, the NC device 1A proceeds to step S170.

[0170] (Step S170) In step S170, the additive manufacturing execution unit 203 receives the head movement path HR8, the scanning speed, the laser output value on the head movement path HR8, and the metal supply amount generated by the process condition generation unit 206. In this way, the additive manufacturing execution unit 203 determines the movement path, scanning speed, laser output value, and metal supply amount of the processing head 8 to be output to the additive manufacturing apparatus 200. The additive manufacturing execution unit 203 causes the additive manufacturing apparatus 200 to start additive manufacturing using the determined movement path, scanning speed, laser output value, and metal supply amount. After executing step S170, the NC device 1A proceeds to step S180.

[0171] (Step S180) In step S180, after the additive manufacturing execution unit 203 completes the additive manufacturing, the production process change unit 205 executes a return operation of the production process. The return operation of the production process includes an operation in which the production process change unit 205 receives a completion notification of the additive manufacturing from the additive manufacturing execution unit 203. The return operation of the production process also includes an operation in which the production process change unit 205 causes the automatic conveyance device 101 to execute a transport operation of the shaped object 15. In the transport operation of the shaped object 15 here, the production process change unit 205 causes the automatic conveyance device 101 to take out the shaped object 15 from the additive manufacturing device 200 and set it on the stage 18 of the removal manufacturing device 202. The return operation of the production process also includes an operation in which the production process change unit 205 transmits a start signal (switching command) of the removal manufacturing process to the removal manufacturing execution unit 207 to prepare for the removal manufacturing process. After executing step S180, the NC device 1A advances the procedure to step S190.

[0172] (Step S190) In step S190, the removal manufacturing execution unit 207 causes the removal manufacturing device 202 to resume removal manufacturing. That is, the removal manufacturing execution unit 207 resumes the analysis of the head movement path HR21 for moving the processing head 21 from the end position of the additive manufacturing in the additive manufacturing execution unit 203 based on the contents of the processing described in the processing program 33, and determines the head movement path HR21 and the scanning speed. In addition, the removal manufacturing execution unit 207 determines the command value of the tool rotation speed required for the removal manufacturing process based on the processing program 33. Then, the removal manufacturing execution unit 207 causes the removal manufacturing device 202 to resume removal manufacturing using the determined movement path, scanning speed, and tool rotation speed. After executing step S190, the NC device 1A advances the procedure to step S200.

[0173] (Step S200) In step S200, the NC unit 1A judges whether or not all of the processes described in the machining program 33 have been completed. If all of the processes described in the machining program 33 have not been completed (step S200, No), the NC unit 1A repeats the processes from steps S130 to S200. The NC unit 1A repeats the processes from steps S130 to S200 until all of the processes described in the machining program 33 have been completed. If all of the processes described in the machining program 33 have been completed (step S200, Yes), the NC unit 1A completes the process of controlling the manufacture of the object 15.

[0174] In this way, the NC device 1A can detect scratches caused by friction or mechanical vibrations that occur when the processing direction in the subtractive manufacturing process is switched, and change the process from the subtractive manufacturing process to the additive manufacturing process. This makes it possible for the NC device 1A to automatically correct the production process and efficiently and accurately produce the shaped object 15 having the desired shape, even if a defect occurs in the finishing process in the subtractive manufacturing device 202.

[0175] Here, a specific example of the object 15 manufactured by the additive manufacturing apparatus 200 will be described. Fig. 15 is a diagram showing an example of a model that the NC apparatus according to the second embodiment causes the subtractive manufacturing apparatus to perform subtractive manufacturing. The model 53 shown in Fig. 15 is an example of the model 15 manufactured by the subtractive manufacturing apparatus 202.

[0176] The processing program 33 used in the subtractive manufacturing process according to the second embodiment includes, for example, a command for finishing the top surface of the object 50 additively manufactured in the first embodiment. Fig. 15 shows an object 53 formed using the processing programs 23 and 33. The processing program 23 is a program for producing the object 50 by stacking layers of material 5 from the 1st layer to the Nth layer. The processing program 33 is a program for producing the object 53 from the object 50 by removing blocks from the 1st block to M (M is a natural number) from the top surface of the object 50.

[0177] The machining program 33 is input to the removal manufacturing execution unit 207 from outside the NC device 1A. In the second embodiment, after the execution of the machining program 33 is started, the removal block M 1 (M 1 A case where scratches occur on the surface of a molded object due to friction or mechanical vibration during a command for a manufacturing process in the vicinity of a block (where M is a natural number from 1 to M) will be described. Hereinafter, the operation of each component of the NC device 1A in this case will be described in a manner different from that of the first embodiment.

[0178] (Status analysis unit 204) The state analysis unit 204 of the NC device 1A collects sensor data 34 from a sensor installed in the removal manufacturing device 202, and estimates the processing state during removal manufacturing based on the sensor data 34. Specifically, the state analysis unit 204 acquires image data obtained by observing the surface shape formed by the removal manufacturing device 202 from the sensor data 34. Furthermore, the state analysis unit 204 extracts shape feature amounts from image data obtained by measuring the molding shape formed by the removal manufacturing device 202. The shape feature amounts extracted here include at least one of curvature, shape height, shape width, etc. The state analysis unit 204 calculates feature amounts including at least one of curvature, shape height, shape width, etc. using an image analysis method such as edge detection and binarization.

[0179] The condition analysis unit 204 analyzes scratches caused by friction or mechanical vibration based on the image data. 1 Blocks and M 1 When comparing with the specified blocks other than the block, M 1 In the block, the Z-axis position indicating the feature height is indented in the negative direction due to friction or mechanical vibration, so the feature height is lower than that of other regions. Therefore, when the variation in the feature height is larger than that of other regions, the state analysis unit 204 generates a printing abnormality signal.

[0180] In the second embodiment, the state analysis unit 204 analyzes the M 1 Although the printing abnormality signal is generated by detecting a defect caused by friction or mechanical vibration at one point of the command to the block, it is also possible to detect defects at one or more other points.

[0181] As described above, according to the second embodiment, the NC device 1A detects scratches on the surface shape caused by friction or mechanical vibration in the subtractive manufacturing process, and switches from the subtractive manufacturing process to the additive manufacturing process. In this case, the NC device 1A creates process conditions including the head movement path HR8 used in the additive manufacturing process based on the process conditions used in the subtractive manufacturing device 202. This makes it possible for the NC device 1A to automatically correct the production process and efficiently and accurately produce the model 53 having the desired shape, even if a defect occurs in the model 15 during finishing.

[0182] Next, the hardware configuration of the NC device 1, 1A will be described. The NC device 1, 1A is realized by a processing circuit. The processing circuit may be a processor and memory that executes a program stored in a memory, or may be dedicated hardware such as a dedicated circuit. The processing circuit is also called a control circuit.

[0183] FIG. 16 is a diagram showing an example of the configuration of a processing circuit when the processing circuit included in the NC device according to the first and second embodiments is realized by a processor and a memory. The processing circuit 90 shown in FIG. 16 is a control circuit and includes a processor 91 and a memory 92. When the processing circuit 90 is configured with the processor 91 and the memory 92, each function of the processing circuit 90 is realized by software, firmware, or a combination of software and firmware. The software or firmware is described as a program and stored in the memory 92. In the processing circuit 90, each function is realized by the processor 91 reading and executing the program stored in the memory 92. That is, the processing circuit 90 includes a memory 92 for storing a program that results in the processing of the NC device 1, 1A being executed. This program can also be said to be a program for causing the NC device 1, 1A to execute each function realized by the processing circuit 90. This program may be provided by a storage medium in which the program is stored, or may be provided by other means such as a communication medium. The above program can also be said to be a program for causing the NC device 1, 1A to execute numerical control processing.

[0184] Here, the processor 91 is, for example, a CPU (Central Processing Unit), a processing device, an arithmetic device, a microprocessor, a microcomputer, or a DSP (Digital Signal Processor), etc. Also, the memory 92 is, for example, a non-volatile or volatile semiconductor memory such as a RAM (Random Access Memory), a ROM (Read Only Memory), a flash memory, an EPROM (Erasable Programmable ROM), an EEPROM (Electrically EPROM), a magnetic disk, a flexible disk, an optical disk, a compact disk, a mini disk, or a DVD (Digital Versatile Disc), etc.

[0185] FIG. 17 is a diagram showing an example of a processing circuit provided in the NC device according to the first and second embodiments, configured with dedicated hardware. The processing circuit 93 shown in FIG. 17 corresponds to, for example, a single circuit, a composite circuit, a programmed processor, a parallel programmed processor, an ASIC (Application Specific Integrated Circuit), an FPGA (Field Programmable Gate Array), or a combination of these. The processing circuit 93 may be partially realized with dedicated hardware and partially realized with software or firmware. In this way, the processing circuit 93 can realize each of the above-mentioned functions by dedicated hardware, software, firmware, or a combination of these.

[0186] The configurations shown in the above embodiments are merely examples, and may be combined with other known technologies, or the embodiments may be combined with each other. Also, parts of the configurations may be omitted or modified without departing from the spirit of the invention. [Explanation of symbols]

[0187] 1,1A NC device, 2 laser oscillator, 3 fiber cable, 4 material supply device, 5 material, 6 gas supply device, 7 piping, 8,21 processing head, 9 beam nozzle, 10 material nozzle, 11 gas nozzle, 12,20 head drive device, 13,18 stage, 14 base material, 15,50,51A~51C,53 molded object, 16 workpiece, 17 hand mechanism, 19 tool, 22 spindle drive device, 23,33 processing program, 24,34 sensor data, 25 hand drive device, 41A,42A additive manufacturing path, 41F,42F laminated shape, 46R1,46R2,47R1,47R2 subtractive manufacturing path, 60 processing system, 90,93 processing circuit, 91 processor, 92 memory, 100,200 Additive manufacturing device, 101 automatic transport device, 102, 202 subtractive manufacturing device, 103, 203 additive manufacturing execution unit, 104, 204 state analysis unit, 105, 205 production process change unit, 106, 206 process condition generation unit, 107, 207 subtractive manufacturing execution unit.

Claims

1. an additive manufacturing execution unit that controls an additive manufacturing apparatus that executes an additive manufacturing process for manufacturing a shaped object by stacking a material melted by irradiating a beam from a first processing head; a removal manufacturing execution unit that controls a removal manufacturing device that executes a removal manufacturing step of cutting the shaped object using a tool disposed on a second processing head; a state analysis unit that receives sensor data obtained by monitoring a processing state during production of the object that is produced by combining two production processes, i.e., the additive manufacturing process and the subtractive manufacturing process, and analyzes the processing state of the object based on the sensor data; a production process change unit that generates a switching command for instructing switching between the two production processes to be executed based on a result of the analysis of the processing state, and outputs the switching command to the additive manufacturing execution unit and the subtractive manufacturing execution unit; When the two production processes are switched, a process condition generation unit determines a second process condition to be used in the subtractive manufacturing process, which is a production process after the switch between the two production processes, based on a first process condition used in the additive manufacturing process, which is a production process before the switch between the two production processes; Equipped with The direction of movement in the processing path used in the subtractive manufacturing process is opposite to the direction of movement in the processing path used in the additive manufacturing process during the manufacturing of the object. A numerical control device comprising:

2. The processing path used in the subtractive manufacturing process includes an offset portion that is a path obtained by offsetting the processing path used in the additive manufacturing process in three-dimensional space; 2. The numerical control device according to claim 1 .

3. The process condition generating unit is As the offset portion, an offset amount capable of removing a deviation amount from a desired value of the height or width of the object in the additive manufacturing process is set.

3. The numerical control device according to claim 2 .

4. The second process condition includes a scanning speed and a spindle rotation speed of the second machining head, The process condition generation unit determines the scanning speed and the spindle rotation speed of the second processing head based on a volume of the object to be removed in the removal manufacturing process.

4. The numerical control device according to claim 1, wherein the numerical control device is a control device for controlling a control operation of the control unit.

5. The state analysis unit is Estimating a welding state or a shape state of the object based on the sensor data; The production process change unit, A determination is made as to whether to continue the additive manufacturing process or to output a switching command based on the result estimated by the state analysis unit.

5. The numerical control device according to claim 1, wherein the numerical control device is a control device for controlling a control operation of the control unit.

6. The sensor data includes at least one of height, width, and temperature data of a specific layer of the object.

3. The numerical control device according to claim 1, wherein the first and second inputs are connected to the first and second inputs.

7. The sensor data includes a load torque applied to a scanning axis of the second processing head of the removal manufacturing device.

3. The numerical control device according to claim 1, wherein the first and second inputs are connected to the first and second inputs.

8. an additive manufacturing execution step in which the numerical control device controls an additive manufacturing device that executes an additive manufacturing process for manufacturing a shaped object by stacking a material melted by irradiating a beam from a first processing head; a subtractive manufacturing execution step in which a numerical control device controls a subtractive manufacturing device that executes a subtractive manufacturing step of cutting the shaped object using a tool arranged on a second machining head; a state analysis step in which a numerical control device receives sensor data obtained by monitoring a processing state during production of the object, which is produced by combining two production processes, i.e., the additive manufacturing process and the subtractive manufacturing process, and analyzes the processing state of the object based on the sensor data; a production process change step in which the numerical control device switches between the two production processes to be executed based on the analysis result of the machining state; When the numerical control device switches between the two production processes, a process condition generation step is performed to determine a second process condition to be used in the subtractive manufacturing process, which is a production process after the switch between the two production processes, based on a first process condition used in the additive manufacturing process, which is a production process before the switch between the two production processes; Including, The direction of movement in the processing path used in the subtractive manufacturing process is opposite to the direction of movement in the processing path used in the additive manufacturing process during the manufacturing of the object. A numerical control method comprising:

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