Manufacturing system for a toroidal propeller for mobility, toroidal propeller for mobility, method for manufacturing the same, method for creating drawings of a toroidal propeller for mobility, server, and program

Abstract

To provide a toroidal propeller that can optimize the shape according to the type and size of mobility such as a ship, and can be made large and inexpensive. 【Solution means】A manufacturing system for a toroidal propeller for mobility, comprising a wire DED method 3D printer, and capable of forming a toroidal propeller having a toroidal shape by the 3D printer.

Description

Technical Field

[0001] The present invention relates to a manufacturing system for a toroidal propeller for mobility, a toroidal propeller for mobility, a manufacturing method thereof, a drawing creation method for a toroidal propeller for mobility, a server, and a program.

Background Art

[0002] The CO2 emissions of ships worldwide account for 1.05 billion tons, which is 3.3% of the total, and it is urgent to address decarbonization. The IMO (International Maritime Organization) has set a goal of improving fuel efficiency by 40% compared to 2008 by 2030 (Non-Patent Document 1). According to the IMO, about 90% of the world's trade volume depends on maritime transportation, and there is also a report that only fuel costs exceed 2 billion yen per year for a single large ship, and approximately 19 trillion yen is spent annually worldwide (Non-Patent Document 2).

[0003] In recent years, high-performance propellers have been regarded as more important. The performance of propellers is examined using various analysis tools, and the performance varies greatly depending on how accurately and smoothly the shape defined therein is processed.

Prior Art Documents

Non-Patent Documents

[0004]

Non-Patent Document 1

Non-Patent Document 2

Summary of the Invention

Problems to be Solved by the Invention

[0005] However, a propeller whose shape is defined to exhibit high performance is generally more difficult to manufacture compared to conventional products. In recent years, the shape of the propeller blades has become more complex, and the number of shapes that are difficult to cast and machine has been increasing.

[0006] Among them, the toroidal propeller has attracted attention in recent years as a fuel efficiency improvement technology. The toroidal propeller is a propeller having a donut-shaped annular structure.

[0007] Conventionally, the manufacturing of propellers has been carried out by casting and cutting processes, but this process is not suitable for manufacturing propellers with a three-dimensional complex shape. In particular, when attempting to manufacture a toroidal propeller with a complex shape using casting and cutting processes, the shape is complex and the manufacturing cost is high. Moreover, as the toroidal propeller becomes larger, the production cost increases exponentially. In addition, there are very few facilities that can hold and pour several tens of tons of molten metal, and it is necessary to modify existing propeller manufacturing facilities, which also incurs a huge cost for manufacturing the base material that serves as a prototype for the toroidal shape with a complex form. Furthermore, it is required to optimize the shape of the toroidal propeller according to the type and size of the ship. Thus, toroidal propellers are very expensive with existing manufacturing methods, making it difficult to increase their size, and it is practically difficult to optimize the shape of the toroidal propeller according to the type and size of the ship. There is not a single large marine toroidal propeller and its manufacturing facility in the world yet.

[0008] Therefore, there is a need for a manufacturing technology for toroidal propellers that can optimize the shape according to the type and size of mobility such as ships, is inexpensive, and can also accommodate large sizes.

Means for Solving the Problem

[0009] The gist of the present invention is as follows. (1) A manufacturing system for a toroidal propeller for mobility, comprising a wire DED type 3D printer, and capable of forming a toroidal propeller having a toroidal shape by the 3D printer. (2) The 3D printer includes a scanable robot arm, a robot head connected to the robot arm, a heat source provided in the robot head, a holding part capable of holding a base material, and a wire supply device. The heat source is configured to heat and melt the wire supplied from the wire supply device. The robot head is configured to build up the wire heated and melted by the heat source onto the base material held by the holding part while being scanned together with the robot arm. The manufacturing system according to (1) above. (3) The base material is the shaft portion of the toroidal propeller or the outer peripheral portion of the toroidal propeller, The 3D printer is configured to be able to build up from the shaft portion to the outer peripheral portion of the toroidal propeller to merge two wing portions to form an integrated toroidal-shaped wing, or to build up from the outer peripheral portion to the shaft portion of the toroidal propeller to merge two wing portions to form an integrated toroidal-shaped wing. The manufacturing system according to (2) above. (4) The 3D printer further includes a first storage device and a first processing device, Based on the model information of the toroidal propeller stored in the first storage device, the first processing device controls the robot arm and the robot head. The manufacturing system according to (3) above. (5) Further includes a server having a second storage device and a second processing device, The following steps (a) to (f) are performed on the server: (a) Generating a plurality of models of similar shapes that are different from the basic model of the toroidal propeller stored in the second storage device; (b) Performing a fluid analysis simulation on the propeller performance when the basic model is mounted on the mobility and the propeller performance when the plurality of models of similar shapes are mounted; (c) Determining whether the propeller performance calculated in the fluid analysis simulation is qualified or unqualified; (d) When all the propeller performances are unqualified, generating a plurality of models of similar shapes with differences for the models with high propeller performance calculated in the fluid analysis simulation until a model with qualified propeller performance is obtained, and performing a fluid analysis simulation on the propeller performance when the plurality of models of similar shapes with differences are mounted on the model with high propeller performance; (e) When a model with qualified propeller performance is obtained, creating a slicer drawing for the 3D printer for the qualified model, and (f) Based on the slicer drawing, forming a toroidal propeller using the 3D printer The manufacturing system according to (4) above, which causes the above to be executed. (6) Further comprising a server having a second storage device and a second processing device, causing the server to perform the following steps (A) to (L): (A) Generating a plurality of second models with a first difference based on the first model of the toroidal propeller stored in the second storage device; (B) Performing a fluid analysis simulation regarding a first propeller performance when the first model is mounted on the mobility and a second propeller performance when the plurality of generated second models are mounted; (C) Determining whether the second propeller performance calculated by the fluid analysis simulation is qualified or unqualified; (D) When all of the second propeller performances are unqualified, extracting a second difference parameter between a model with a high second propeller performance among the plurality of second models and the first model, and generating a plurality of third models with a second difference based on the model with a high second propeller performance and the extracted second difference parameter; (E) Performing a fluid analysis simulation regarding a third propeller performance when the plurality of generated third models are mounted on the mobility; (F) Determining whether the third propeller performance calculated by the fluid analysis simulation is qualified or unqualified; (G) When all of the third propeller performances are unqualified, extracting a third difference parameter between a model with a high third propeller performance among the plurality of third models and a model with a high second propeller performance among the plurality of second models, and generating a plurality of fourth models with a third difference based on the model with a high third propeller performance and the extracted third difference parameter; (H) Performing a fluid analysis simulation regarding a fourth propeller performance when the plurality of generated fourth models are mounted on the mobility; (I) Determining whether the fourth propeller performance calculated in the fluid analysis simulation is qualified or unqualified; (J) When all of the fourth propeller performances are unqualified, repeating (G) to (I) until a model with qualified propeller performance is obtained; (K) When an nth model with qualified nth propeller performance is obtained, creating a slicer drawing for the 3D printer for the qualified nth model, where n is an integer of 2 or more, and (L) Forming a toroidal propeller using the 3D printer based on the slicer drawing The manufacturing system according to (4) above, which causes the above to be executed. (7) The first model includes data of a 3D-CAD drawing including a first configuration including at least one of the shape of the toroidal propeller, the number of blades, the propeller length, the thickness, the bend, the surface property of the blade, the void, the diameter of the shaft, the length of the shaft, and the material, the manufacturing system according to (6) above. (8) The plurality of second models have the first difference in a second configuration including at least one of the shape of the toroidal propeller, the number of blades, the propeller length, the thickness, the bend, the surface property of the blade, the void, the diameter of the shaft, the length of the shaft, and the material, the manufacturing system according to (6) or (7) above. (9) The plurality of third models have the second difference in a third configuration including at least one of the shape of the toroidal propeller, the number of blades, the propeller length, the thickness, the bend, the surface property of the blade, the void, the diameter of the shaft, the length of the shaft, and the material, the manufacturing system according to any one of (6) to (8) above. (10) The plurality of fourth models have the third difference in a fourth configuration including at least one of the shape of the toroidal propeller, the number of blades, the propeller length, the thickness, the bend, the surface property of the blade, the void, the diameter of the shaft, the length of the shaft, and the material, the manufacturing system according to any one of (6) to (9) above. (11) The first propeller performance, the second propeller performance, the third propeller performance, and the fourth propeller performance include the evaluation of the fuel consumption, vibration, noise, or a combination thereof of the mobility equipped with the toroidal propeller, and the manufacturing system according to any one of (6) to (10) above. (12) The determination of pass or fail of the second propeller performance, the third propeller performance, and the fourth propeller performance is performed based on the evaluation, and the manufacturing system according to (11) above. (13) Generating the third model includes extracting a second difference parameter between the model with the highest second propeller performance among the plurality of second models and the first model, and generating a plurality of third models with the second difference based on the model with the highest second propeller performance and the extracted second difference parameter, and the manufacturing system according to any one of (6) to (12) above. (14) Generating the fourth model includes extracting a third difference parameter between the model with the highest third propeller performance among the plurality of third models and the model with the highest second propeller performance among the plurality of second models, and generating a plurality of fourth models with the third difference based on the model with the highest third propeller performance and the extracted third difference parameter, and the manufacturing system according to any one of (6) to (13) above. (15) Creating a slicer drawing for the 3D printer for the qualified model includes creating a slicer drawing for the 3D printer for the model with the highest propeller performance among the qualified models, and the manufacturing system according to any one of (6) to (14) above. (16) Generating the plurality of second models includes, when the data of the first model is input into the second storage device, the processing device generating the plurality of second models by changing at least one parameter including the shape of the toroidal propeller, the number of blades, the propeller length, the thickness, the curvature, the surface property of the blade, the void, the diameter of the shaft, the length of the shaft, and the material, and the manufacturing system according to any one of (6) to (15) above. (17) Generating the plurality of third models includes, when the model with the highest second propeller performance and the extracted second differential parameters are input to the second storage device, the processing device changing at least one parameter including the shape of the toroidal propeller, the number of blades, the propeller length, the thickness, the curvature, the surface property of the blade, the void, the diameter of the shaft, the length of the shaft, and the material, and generating the plurality of third models. The manufacturing system according to any one of (6) to (16) above. (18) Generating the plurality of fourth models includes, when the model with the highest third propeller performance and the extracted third differential parameters are input to the second storage device, the processing device changing at least one parameter including the shape of the toroidal propeller, the number of blades, the propeller length, the thickness, the curvature, the surface property of the blade, the void, the diameter of the shaft, the length of the shaft, and the material, and generating the plurality of fourth models. The manufacturing system according to any one of (6) to (17) above. (19) The toroidal propeller has a diameter of 2000 mm or more. The manufacturing system according to any one of (1) to (18) above. (20) The mobility is a ship or an aircraft. The manufacturing system according to any one of (1) to (19) above. (21) The mobility is a large ship or a giant ship. The manufacturing system according to any one of (1) to (19) above. (22) A toroidal propeller for mobility having a diameter of 2000 mm or more. (23) The mobility is a ship or an aircraft. The toroidal propeller for mobility according to (22) above. (24) The mobility is a large ship or a giant ship. The toroidal propeller for mobility according to (22) above. (25) A method for manufacturing a toroidal propeller for mobility, including forming a toroidal propeller having a toroidal shape using a wire DED method 3D printer. (26) A method for creating a drawing for a wire DED method 3D printer of a toroidal propeller for mobility, (A) Generate a plurality of second models with a first difference based on the first model of the toroidal propeller. (B) Perform a fluid analysis simulation regarding the first propeller performance when the first model is mounted on the mobility and the second propeller performance when the plurality of generated second models are mounted. (C) Determine whether the second propeller performance calculated in the fluid analysis simulation passes or fails. (D) When all of the second propeller performances fail, extract the second difference parameters between the model with the highest second propeller performance among the plurality of second models and the first model, and generate a plurality of third models with a second difference based on the model with the highest second propeller performance and the extracted second difference parameters. (E) Perform a fluid analysis simulation regarding the third propeller performance when the plurality of generated third models are mounted on the mobility. (F) Determine whether the third propeller performance calculated in the fluid analysis simulation passes or fails. (G) When all of the third propeller performances fail, extract the third difference parameters between the model with the highest third propeller performance among the plurality of third models and the model with the highest second propeller performance among the plurality of second models, and generate a plurality of fourth models with a third difference based on the model with the highest third propeller performance and the extracted third difference parameters. (H) Perform a fluid analysis simulation regarding the fourth propeller performance when the plurality of generated fourth models are mounted on the mobility. (I) Determine whether the fourth propeller performance calculated in the fluid analysis simulation passes or fails. (J) When all of the fourth propeller performances fail, repeat (G) to (I) until a model with a passing propeller performance is obtained, and (K) When a qualified n-th model with the n-th propeller performance is obtained, creating a slicer drawing for the 3D printer for the qualified n-th model, where n is an integer of 2 or more. A drawing creation method including the above. (27) A server in a drawing creation system for a 3D printer of the wire DED method for a toroidal propeller for mobility, (A) Second model generation means for generating a plurality of second models with a first difference based on the first model of the toroidal propeller stored in the storage device of the server, (B) First and second propeller performance analysis means for performing a fluid analysis simulation on the first propeller performance when the first model is mounted on the mobility and the second propeller performance when the generated plurality of second models are mounted, (C) Second propeller performance determination means for determining whether the second propeller performance calculated by the fluid analysis simulation is qualified or unqualified, (D) When all of the second propeller performances are unqualified, extracting second difference parameters between the model with the highest second propeller performance among the plurality of second models and the first model, and generating a plurality of third models with a second difference based on the model with the highest second propeller performance and the extracted second difference parameters, (E) Third propeller performance analysis means for performing a fluid analysis simulation on the third propeller performance when the generated plurality of third models are mounted on the mobility, (F) Third propeller performance determination means for determining whether the third propeller performance calculated by the fluid analysis simulation is qualified or unqualified, (G) When all of the third propeller performances are unqualified, extracting third difference parameters between the model with the highest third propeller performance among the plurality of third models and the model with the highest second propeller performance among the plurality of second models, and generating a plurality of fourth models with a third difference based on the model with the highest third propeller performance and the extracted third difference parameters, (H) Fourth propeller performance analysis means for performing a fluid analysis simulation regarding the fourth propeller performance when the plurality of fourth models generated are mounted on the mobility, (I) Fourth propeller performance determination means for determining pass or fail of the fourth propeller performance calculated by the fluid analysis simulation, (J) Repetition means for repeating the above (G) to (I) until a model with pass propeller performance is obtained when all of the fourth propeller performances are fail, and (K) Drawing creation means for creating a slicer drawing for the 3D printer for the nth model when the nth model with pass nth propeller performance is obtained, where n is an integer of 2 or more, A server comprising the above. (28) In a server in a drawing creation system for a 3D printer of a wire DED method for a toroidal propeller for mobility, (A) A second model generation process for generating a plurality of second models with a first difference based on the first model of the toroidal propeller stored in the storage device of the server, (B) First and second propeller performance analysis processes for performing a fluid analysis simulation regarding the first propeller performance when the first model is mounted on the mobility and the second propeller performance when the plurality of generated second models are mounted, (C) A second propeller performance determination process for determining pass or fail of the second propeller performance calculated by the fluid analysis simulation, (D) When all of the second propeller performances are fail, extract the second difference parameter between the model with high second propeller performance among the plurality of second models and the first model, and based on the model with high second propeller performance and the extracted second difference parameter, a third model generation process for generating a plurality of third models with a second difference, (E) A third propeller performance analysis process for performing a fluid analysis simulation regarding the third propeller performance when the plurality of generated third models are mounted on the mobility, (F) A third propeller performance determination process for determining pass or fail of the third propeller performance calculated by the fluid analysis simulation. (G) When all of the third propeller performances are fails, extract a third difference parameter between a model with a high third propeller performance among the plurality of third models and a model with a high second propeller performance among the plurality of second models, and generate a plurality of fourth models with a third difference based on the model with a high third propeller performance and the extracted third difference parameter in a fourth model generation process. (H) A fourth propeller performance analysis process for performing a fluid analysis simulation regarding the fourth propeller performance when the generated plurality of fourth models are mounted on the mobility. (I) A fourth propeller performance determination process for determining pass or fail of the fourth propeller performance calculated by the fluid analysis simulation. (J) When all of the fourth propeller performances are fails, a repetition process of repeating (G) to (I) until a model with a passing propeller performance is obtained, and (K) When an nth model with a passing nth propeller performance is obtained, a drawing creation process of creating a slicer drawing for the 3D printer for the passed nth model, where n is an integer of 2 or more. A program that causes the above to be executed.

Advantages of the Invention

[0010] According to the present invention, it is possible to provide a toroidal propeller that can optimize the shape according to the type and size of mobility such as a ship, and can be made large-sized at low cost.

Brief Description of the Drawings

[0011]

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DETAILED DESCRIPTION OF THE INVENTION

[0012] The present disclosure relates to a manufacturing system for a toroidal propeller for mobility, which includes a 3D printer using a wire DED (Direct Energy Deposition) method and is capable of forming a toroidal propeller having a toroidal shape by the 3D printer.

[0013] According to the manufacturing system of the present disclosure (also referred to as the present manufacturing system), it can include an apparatus equipped with a 3D printer using a wire DED method (hereinafter also referred to as a wire DED printer or a 3D printer). It is possible to optimize the shape according to the type and size of mobility such as a ship, and it is possible to manufacture small and large toroidal propellers at low cost.

[0014] In the conventional screw propeller 60 shown in FIG. 7, lift is generated when the blade 61 rotates, and this lift is used as thrust. Negative pressure is generated on the upper surface of the rotating blade 61, and positive pressure is generated on the lower surface, thereby generating lift. When this pressure difference collides at the end of the blade 61, a vortex called a tip vortex is generated, and it is known that the larger the tip vortex is generated, the more adverse effects it has on the lift of the blade. It is also known that when a tip vortex occurs in water, a phenomenon called cavitation occurs in which water undergoes a phase change to become a gas due to negative pressure. When cavitation occurs, the thrust deteriorates rapidly.

[0015] On the other hand, the toroidal propeller does not have an end of the blade where the pressure difference collides. FIG. 4 shows a side schematic view of the toroidal propeller 50. FIG. 5 shows a front schematic view of the toroidal propeller 50. FIG. 6 shows a perspective view schematically representing the toroidal propeller 50.

[0016] The toroidal shape of the toroidal propeller 50 is such that the blade 52 having the axis 54 has a closed ring shape, so there is no place where positive pressure and negative pressure collide, the generation of tip vortices can be suppressed, and it is difficult for adverse effects to occur in the generation of lift. When the toroidal propeller 50 is used in water, the occurrence of cavitation can be suppressed, so even if the rotational speed is increased, a decrease in efficiency hardly occurs, and it is possible to generate thrust with high efficiency.

[0017] The fluid analysis of a propeller and the evaluation of thrust (propulsive force) may be performed on a full-scale or miniature model. In engineering design, particularly in ship design, verification has conventionally been carried out using a miniature model such as a 1 / 100 model. In fluid analysis and thrust measurement, when the Reynolds number, which is a variable parameter, is substantially equal, the engineering scaling law holds, and it is known that verification with a miniature model can be applied to a full-scale model.

[0018] On the other hand, in the case of the toroidal propeller 50, the blades 52 of the shaft 54 have a closed ring shape. When attempting to form such a toroidal shape composed of a closed circuit using conventional casting and cutting processes, looseness is likely to occur, and in the cutting process, there may be a portion where the drill cannot reach. In contrast, according to the wire DED printer, a toroidal propeller with a shape that is difficult to reproduce using conventional casting and cutting processes can be manufactured at low cost, the shape can be optimized according to the type and size of mobility such as a ship, and a large toroidal propeller can also be manufactured at low cost.

[0019] According to this manufacturing system, the shape can be optimized according to the type and size of mobility such as a ship, and a large toroidal propeller for mobility can be manufactured at low cost. According to this manufacturing system, a toroidal propeller for mobility having a diameter of preferably 2000 mm or more, more preferably 2500 mm or more, and even more preferably 3000 mm or more can be obtained at low cost. The diameter of the toroidal propeller is the diameter of the circle described by the tip of the blade 52 when the propeller makes one revolution.

[0020] In the present application, a mobility device is a moving body that obtains thrust from a propeller and can be manned or unmanned. According to this manufacturing system, not only small but also large toroidal propellers can be manufactured. Therefore, the toroidal propellers manufactured by this manufacturing system can be used for various mobility devices, preferably for marine vessels or aircraft, for large ships, and also for huge ships. Ships include, for example, cargo ships, passenger ships, fishing boats, patrol boats, fireboats, frigates, submarines, workboats, etc. Aircraft include, for example, small flying bodies such as airplanes, drones, hoverbikes, etc. A large ship means a ship with a gross tonnage of 20 tons or more, and a huge ship means a ship with a total length of 200 m or more.

[0021] The wire DED printer is a type of 3D printer shaping method. The wire DED method is also called a directed energy deposition method, a deposition method, etc., and is a process of melting, bonding, and depositing materials using thermal energy.

[0022] As schematically shown in FIG. 1, the wire DED printer 100 can include a scanable robot arm 1, a robot head 2 connected to the robot arm 1, a heat source 21 provided in the robot head 2, a holding part (not shown) capable of holding a base material, and a wire supply device (not shown).

[0023] In the wire DED printer 100, in the robot head 2 having the robot arm 1 at its end, a wire 22 of metal or plastic, which is a raw material, is supplied through a nozzle by a wire supply device, and at the heating and melting part 30 at the tip of the robot head 2, energy from the heat source 21 is applied to the wire 22 to heat it while sending a shielding gas. The melted wire material is solidified and built up on the base material 40, and by repeating this lamination, parts can be three-dimensionally shaped. By moving and / or rotating the base material 40, parts can be formed at various angles. The base material 40 may be a member separate from the part or may be a part of the part. The robot arm 1 and the robot head 2 may be connected or integrated. There may be one or more robot arms 1 and robot heads 2. The heat source 21 can be a laser, an arc, an electron beam, or a plasma. There may be one heat source 21 or multiple heat sources 21. The heat source 21 may combine multiple types of heat sources. The heat source 21 illustrated in FIG. 1 is a laser oscillator.

[0024] Arcs include an electric arc and a plasma arc. Although they are not relatively good at precise control, they have a large amount of energy and can melt a large amount of wire material, so the deposition rate can be increased. An electron beam has a large amount of energy and precise control is possible, but a vacuum environment is required. A laser has a relatively small amount of energy, but precise control is possible and a vacuum environment is not required. The shielding gas is, for example, an inert gas such as argon or a mixed gas thereof.

[0025] The wire DED method can use a heat source to melt the wire, which is the raw material, and compared with other AM technologies such as the PBF (Powder Bed Fusion) method, it is possible to additively manufacture large parts at a high deposition rate. Also, compared with the PBF method, which spreads metal powder in a bath and sinters it with a laser to form a three-dimensional shape, the wire DED method does not require expensive metal powder and does not require a bath, so there is no restriction on the bath size, and there is almost no waste material except for the cutting process of the surplus part. Therefore, it has the advantages of low cost, the ability to handle large parts, and less waste material. The wire DED method can also use commercially available welding wire, and the material options are wide.

[0026] As the wire DED printer 100, a robot arm type large AM (Additive Manufacturing) device capable of accommodating parts with dimensions preferably 1000 mm or more, more preferably 2000 mm or more can be used. The AM device is provided with a robot head on the robot arm, and the robot head can have a heat source and a wire supply device. While heating and melting the wire supplied from the wire supply device with the energy from the heat source, the robot head can be scanned to build up the wire material on the base material.

[0027] The base material can be the shaft part of the toroidal propeller or the outer peripheral part of the toroidal propeller. The wire DED printer 100 can be configured to form the toroidal propeller with a closed-loop blade by forming from the shaft part of the toroidal propeller toward the outer peripheral part and merging the two blade parts, or by forming from the outer peripheral part of the toroidal propeller toward the shaft part.

[0028] In the formation of the toroidal propeller by the wire DED printer 100, preferably, as schematically shown in FIG. 2, it is possible to form the toroidal propeller 50 by forming from the shaft 54 of the toroidal propeller toward the outer peripheral part and merging the two blade parts 521 to form the integrated closed-loop blade 52.

[0029] FIG. 10 shows an external view photograph of a toroidal propeller being manufactured in the present manufacturing system. FIG. 10 is an external view photograph of two stainless-steel blade portions 521 being formed on the surface of a stainless-steel shaft 54, and shows the state immediately before the blade portions 521 merge.

[0030] FIG. 11 shows an external view photograph of a toroidal propeller in which the two blade portions 521 are continuously build-up welded from the state shown in FIG. 10 to form a blade 52. FIG. 12 shows an external view photograph of the toroidal propeller of FIG. 11 observed from the axial direction.

[0031] The toroidal blade 52 can be coaxially arranged around the shaft 54. In this way, by forming from the shaft 54 toward the outer peripheral portion and merging the two blade portions 521 to form an integrated closed-loop blade portion 52, a closed-loop structure that is difficult to form by conventional casting and cutting processes can be formed. Therefore, according to the wire DED printer 100, a toroidal propeller shape having a complex shape composed of a closed loop can be inexpensively formed.

[0032] As illustrated in FIG. 10, the wire DED printer 100 can include a holding portion 70 that holds the shaft 54. The holding portion 70 has a moving mechanism and / or a rotating mechanism with a chuck, and can grip the end portion of the held shaft 54 to move and / or rotate the shaft 54. The blade 52 may be formed while rotating the shaft 54 held by the holding portion 70 about the axis.

[0033] When forming the blade 52 on the surface of the shaft 54 with the wire DED printer 100, it is preferable to perform build-up welding vertically downward with respect to the surface of the shaft 54 or at a slight angle from vertically downward. When forming a plurality of blades 52 around the surface of the shaft 54, the blade 52 can be formed while rotating the shaft 54 held by the holding portion about the axis.

[0034] One of the plurality of blades 52 may be formed first, and then the shaft 54 may be rotated to form the other blades 52 in series order.

[0035] Alternatively, a plurality of blades 52 may be formed in parallel, preferably in an axisymmetric manner. When forming three blades 52 on the surface of the shaft 54, the three blades 52 can be formed simultaneously by gradually building up the material while rotating the shaft 54. If it is desired to cool the blade 52 during the build-up forming process, the shaft 54 can be rotated to form other blades 52. Also, when manufacturing a toroidal propeller with a large size, for example, a diameter of 2000 mm or more, since the mass of the blade 52 becomes large and the position of the center of gravity is likely to change significantly, it is preferable to form a plurality of blades 52 in parallel, preferably in an axisymmetric manner, while rotating the shaft 54 in order to maintain balance.

[0036] The wire 22 used in the wire DED printer 100 can be a metal wire conventionally used for welding. Metal wires are inexpensive and have a wide range of material options. Examples of metal wires include stainless steel, aluminum alloys, or corrosion-resistant alloys such as nickel-based, copper-based, and nickel-copper alloy-based alloys. The material of the shaft 54 and the material of the blade 52 formed on at least the surface of the shaft 54 can be the same material or a combination of different materials with excellent weldability to each other. For example, the shaft 54 and the blade 52 can be made of SUS316L. Examples of plastic wires include filaments or pellets.

[0037] This manufacturing system may be equipped with a cooling device. Since the toroidal propeller mounted on the ship can be repeatedly loaded in a seawater environment, high durability is required. Therefore, it is preferable to refine the crystal grains of the structure constituting the shaft 54 and the blade 52 of the toroidal propeller. The wire DED printer 100 can rapidly cool the formed object and can refine the crystal grains. The cooling rate of the formed object is preferably 1×10 3 ~1×10 5 °C / second. By cooling the formed object at the above-mentioned preferable cooling rate, the crystal grains can be refined more favorably.

[0038] This manufacturing system may include a heat treatment device. In the wire DED printer 100, heat treatment may be performed after the above cooling. By performing heat treatment, solid solution strengthening, precipitation strengthening, work hardening, and grain size control of the structure constituting the shaft 54 and the blades 52 of the toroidal propeller can be achieved.

[0039] The wire DED printer 100 can be configured to be adjustable for shaping conditions including the angle of the build-up robot head, the build-up welding speed, the feeding speed of the wire 22 fed to the robot head 2, the build-up welding current and voltage, the moving direction of the robot head 2, the weaving conditions of the robot head 2, or a combination thereof. In the formation of the toroidal propeller 50 by the wire DED printer 100, preferably, micro-machining of the surface of the blade 52 is performed while three-dimensionally shaping, and the surface properties of the blade 52 can be controlled. By controlling the surface properties of the blade 52, a toroidal propeller 50 having blades 52 with excellent fluid characteristics can be formed. By performing micro-machining of the surface of the blade 52 while three-dimensionally shaping, post-processing for controlling the surface properties of the blade 52 is unnecessary, and a toroidal propeller 50 having surface properties with excellent fluid characteristics can be formed at low cost. By changing the shaping conditions of the wire DED printer 100, the surface properties of the blade 52 can be changed.

[0040] The wire DED printer 100 preferably includes a first storage device, a first processing device, and a first communication device capable of transmitting and receiving to and from the outside, and can perform digitized quality control. The wire DED printer 100 may also include a reading and writing device capable of reading and writing portable media such as USB, CD, and DVD. The wire DED printer 100 may also have other devices such as an output device.

[0041] The first processing device can store the model data transmitted from the outside via the first communication device or the model data input via a portable medium and a reading / writing device in the first storage device. The first processing device can control a robot arm and a robot head based on the model information stored in the first storage device to execute three-dimensional modeling.

[0042] Preferably, it includes the first processing device controlling the robot arm 1, the robot head 2, and the holding part of the base material 40 based on the model information of the toroidal propeller stored in the first storage device. The model information may include data regarding the shape and material of the toroidal propeller.

[0043] The control of the robot arm 1 may include the control of the scanning of the robot arm 1. The control of the robot head 2 may include the supply timing and supply speed of the wire 22 by the wire supply device, the energy supply range, supply timing, and supply amount to the wire 22 by the heat source 21, and the supply range, supply timing, and supply amount of the shielding gas. The control of the holding part of the base material 40 may include moving and rotating the holding part so that the base material 40 is at a desired position and angle.

[0044] When executing three-dimensional modeling based on the program included in the first storage device, the first processing device can highly digitally control four parameters: the heat flow rate by the heat source 21, the scanning speed, the bead width, and the bead thickness, to form a high-quality shaped object.

[0045] The first storage device stores programs such as a driver program, an operating system program, and an application program including the operation program of the wire DED printer 100. The first storage device may store model data, measurement data during three-dimensional modeling including process parameters, temperature, humidity, electrical resistance, image data, etc., wire material data, device information, peripheral model data including interference object model data, and maintenance information of the wire DED printer 100.

[0046] The first processing device includes one or more processors and their peripheral circuits. The first processing device comprehensively controls the overall operation of the wire DED printer 100 and is, for example, a CPU (Central Processing Unit).

[0047] The first processing device executes various processes based on programs (such as driver programs, operating system programs, application programs, etc.) stored in the first storage device. Also, the first processing device can execute multiple programs (such as application programs) in parallel. The first storage device may be built into the wire DED printer 100, may be built into another wire DED printer connected to the wire DED printer 100 by wire or wirelessly, may be an external storage device connected to the wire DED printer 100 by wire or wirelessly, or may be included in a server or cloud server connected to the wire DED printer 100 via a communication network such as the Internet.

[0048] The first processing device can store (memorize) the input external model data in the first storage device. Also, based on the model data stored in the first storage device, the first processing device can control the first storage device, the operation of the robotic arm equipped with the robot head, and the operation of the holding unit so as to execute three-dimensional modeling.

[0049] This manufacturing system can further include a server for storing and generating model data of a toroidal propeller, performing a fluid analysis simulation regarding the propeller performance of the generated model, determining whether the propeller performance calculated by the fluid analysis simulation is qualified or unqualified, and creating a slicer drawing for the wire DED printer of the generated model. This manufacturing system can also further include a server for causing a wire DED printer to form a toroidal propeller based on the created slicer drawing. The two servers may be integrated or separate.

[0050] Figure 9 shows a schematic diagram of an example of the present manufacturing system 10. The present manufacturing system 10 preferably includes a wire DED printer 100 and a server 200. The server 200 may be integrated with the wire DED printer 100 or may be common to the server of the wire DED printer 100. The wire DED printer 100 and the server 200 do not necessarily need to be connected via the network 300, but preferably, as shown in Figure 9, the wire DED printer 100 and the server 200 are connected via the network 300.

[0051] The server 200 may include a second storage device, a second processing device, and a second communication device capable of transmitting and receiving with the outside. The server 200 may be connected to a communication network such as the Internet. The server 200 may also include a reading and writing device capable of reading and writing portable media such as USB, CD, and DVD. The server 200 may also have other devices such as an output device.

[0052] The second storage device may have the same configuration as the above-described first storage device. The second processing device can store the model data stored in the second storage device in the first storage device via the first communication device or the reading and writing device of the wire DED printer. The first storage device, the first processing device, and the first communication device may be common to the second storage device, the second processing device, and the second communication device.

[0053] The server 200 may also include a reading and writing device capable of reading and writing portable media such as USB, CD, and DVD. The model data stored and generated in the server can be transmitted to the wire DED printer 100 via a wireless or wired network or input via a portable medium such as USB, CD, and DVD.

[0054] The present manufacturing system preferably further includes a server having a second storage device and a second processing device. The following steps (a) to (f) are performed on the server: (a) Generating a plurality of models with similar shapes that differ from the basic model of the toroidal propeller stored in the second storage device; (b) Performing a fluid analysis simulation regarding the propeller performance when the basic model is mounted on the mobility and the propeller performance when the plurality of models with similar shapes are mounted; (c) Determining whether the propeller performance calculated in the fluid analysis simulation is qualified or unqualified; (d) When all of the propeller performances are unqualified, generating a plurality of models with similar shapes that differ from the model with high propeller performance calculated in the fluid analysis simulation until a model with qualified propeller performance is obtained, and performing a fluid analysis simulation regarding the propeller performance when the plurality of models with similar shapes that differ from the model with high propeller performance are mounted; (e) When a model with qualified propeller performance is obtained, creating a slicer drawing for a 3D printer for the qualified model, and (f) Forming a toroidal propeller using the 3D printer based on the slicer drawing are executed.

[0055] FIG. 3 shows a flow of an outline of the processes (a) to (f) above. By performing the steps (a) to (f), a large toroidal propeller having excellent propeller performance optimized for each mobility at low cost can be formed more easily. The optimal configuration of the propeller is different for each mobility, and individual customization according to the configuration of the mobility such as the type, size, and engine of the mobility may be required, which may increase the burden of the design process. However, according to the manufacturing system including the above (a) to (f), a toroidal propeller optimized for each mounted mobility can be efficiently formed.

[0056] This manufacturing system more preferably further includes a server having a second storage device and a second processing device, and the following steps (A) to (L) are performed on the server: (A) Generating a plurality of second models with a first difference based on the first model of the toroidal propeller stored in the second storage device; (B) Performing a fluid analysis simulation regarding the first propeller performance when the first model is mounted on the mobility and the second propeller performance when the plurality of generated second models are mounted; (C) Determining whether the second propeller performance calculated in the fluid analysis simulation is qualified or unqualified; (D) When all of the second propeller performances are unqualified, extracting a second difference parameter between the model with the highest second propeller performance among the plurality of second models and the first model, and generating a plurality of third models with a second difference based on the model with the highest second propeller performance and the extracted second difference parameter; (E) Performing a fluid analysis simulation regarding the third propeller performance when the plurality of generated third models are mounted on the mobility; (F) Determining whether the third propeller performance calculated in the fluid analysis simulation is qualified or unqualified; (G) When all of the third propeller performances are unqualified, extracting a third difference parameter between the model with the highest third propeller performance among the plurality of third models and the model with the highest second propeller performance among the plurality of second models, and generating a plurality of fourth models with a third difference based on the model with the highest third propeller performance and the extracted third difference parameter; (H) Performing a fluid analysis simulation regarding the fourth propeller performance when the plurality of generated fourth models are mounted on the mobility; (I) Determining whether the fourth propeller performance calculated in the fluid analysis simulation is qualified or unqualified; (J) When all of the fourth propeller performances are unqualified, repeating (G) to (I) until a model with qualified propeller performance is obtained; (K) When a n-th model that passes the n-th propeller performance is obtained, create a slicer drawing for the 3D printer for the passed n-th model, where n is an integer of 2 or more, and (L) Based on the slicer drawing, form a toroidal propeller using the 3D printer to be executed.

[0057] By performing the steps (A) to (L) above, it is possible to more easily form a large toroidal propeller having excellent propeller performance that is inexpensive and optimized for each mobility. The optimal configuration of the propeller differs for each mobility, and individual customization according to the configuration of the mobility such as the type, size, and engine of the mobility may be required, which can increase the burden of the design process. However, according to the manufacturing system including (A) to (L) above, it is possible to efficiently form a toroidal propeller optimized for each mounted mobility.

[0058] Fig. 3 shows the flow of the outlines of the above processes (a) to (f) and (A) to (L). The above processes (a) to (f) and (A) to (L) can be designs using a genetic algorithm. In step (a) or (A), a plurality of second models with a first difference are generated from the first model which is the basic model.

[0059] The second model has a first difference from the first model with the first model as a reference. There are a plurality of the first differences, and there are also a plurality of second models corresponding thereto. The first difference can be a predetermined difference or a random difference.

[0060] In the generation of the second model, a plurality of second models can be generated using a program so that the first model has a predetermined difference or a random difference as the first difference.

[0061] In the generation of the third model, a plurality of second models can be generated using a program so that the second models have a predetermined difference or a random difference as the second difference with respect to the second model. The same applies to the generation of models from the fourth model onwards.

[0062] The above program may be a commercially available generative AI or a trained calculation model subjected to machine learning. The generative AI can be, for example, ChatGPT, Gemini, Adobe Firefly, Canva, Midjourney, etc. The trained calculation model may be, for example, a trained calculation model subjected to machine learning so as to generate a plurality of second models having a predetermined difference or a random difference with respect to the first model when the first model is input.

[0063] The first model is a basic model of a toroidal propeller. The first model may be prepared as one or more basic models for each mobility.

[0064] The first model can be data including a first configuration including at least one of the shape of the toroidal propeller, the number of blades, the propeller length, the thickness, the curvature, the surface property of the blade, the void, the diameter of the shaft, the length of the shaft, and the material, and can be, for example, data of 3D-CAD drawings. The first configuration may further include at least one of mass, density, and rigidity. The data of the 3D-CAD drawings can be converted into data for a wire DED printer by a second processing device.

[0065] Generating a plurality of second models with a first difference based on the first model of the toroidal propeller may include generating a plurality of second models having a first difference from the first model in the first configuration.

[0066] The fluid analysis simulation in the above process can be a conventionally used simulation, such as Matlab (registered trademark), Autodesk CFD (registered trademark), etc. Fluid analysis simulation is performed on the first propeller performance when the first model is mounted on the mobility and the respective second propeller performances when a plurality of second models are each mounted on the mobility, and the first propeller performance and the second propeller performances corresponding to each of the plurality of second models can be calculated. When the second propeller performance is unqualified, fluid analysis simulation is performed on the respective third propeller performances when a plurality of third models are each mounted on the mobility, and the third propeller performances corresponding to each of the plurality of third models can be calculated. When the third propeller performance is unqualified, fluid analysis simulation is performed on the respective fourth propeller performances when a plurality of fourth models are each mounted on the mobility, and the fourth propeller performances corresponding to each of the plurality of fourth models can be calculated.

[0067] In the fluid analysis simulation, analysis can be performed including the configuration of the mobility, the configuration of the toroidal propeller mounted on the mobility, and other configurations of the mobility that affect the propulsion force other than the toroidal propeller, such as the configuration of the hull of a ship, a ladder, a side thruster, etc.

[0068] For the selection of the model with high propeller performance in step (d) or the selection of the model with high second propeller performance in step (D), one or more models with high propeller performance may be selected, or any model among the plurality of models with high propeller performance, for example, any one of the top 1 to 3 in performance, may be selected, but preferably the model with the highest propeller performance is selected. The same applies to the model with high third propeller performance in step (G).

[0069] The difference is the difference with respect to the base model that each of the plurality of models with similar shapes has. The first difference is the difference with respect to the first model that each of the plurality of second models has.

[0070] The second difference is the difference between the first model and the second model with high second propeller performance among the plurality of second models. The second difference also becomes the difference with respect to the second model with high second propeller performance that each of the plurality of third models has. The second difference is the difference corresponding to the second difference parameter. The second difference parameter is what parameterizes the second difference between the second model with high second propeller performance and the first model.

[0071] The third difference is the difference between the third model with high third propeller performance and the second model with high second propeller performance among the plurality of third models. The third difference also becomes the difference with respect to the third model with high third propeller performance that each of the plurality of fourth models has. The third difference is the difference corresponding to the third difference parameter. The third difference parameter is what parameterizes the third difference between the third model with high third propeller performance and the second model with high second propeller performance.

[0072] FIG. 8 shows an overview of the processes of the above steps (A) to (F) and up to the middle of (G), and an image of generating models with differences in each step.

[0073] In steps (A), (B), and (C), based on the first model of the toroidal propeller, a plurality of second models with the first difference are generated, and a fluid analysis simulation is performed on the first propeller performance when the first model is mounted on the mobility and the second propeller performance when the plurality of second models are mounted on the mobility, and it is determined whether the second propeller performance calculated by the fluid analysis simulation passes or fails. In FIG. 8, an example of generating three second models is shown.

[0074] If the second propeller performance fails in all cases, in steps (D), (E), and (F), select a model with high second propeller performance among multiple second models, extract the second difference parameter between the selected model with high second propeller performance and the first model, generate a plurality of third models with a second difference based on the second model with high second propeller performance and the extracted second difference parameter, then perform a fluid analysis simulation regarding the third propeller performance when the generated plurality of third models are mounted on the mobility, and determine whether the third propeller performance calculated by the fluid analysis simulation passes or fails. In FIG. 8, an example of generating three third models is shown.

[0075] In FIG. 8, an example of selecting the second model with the highest second propeller performance in step (D) and generating three third models with a second difference based on the selected second model with the highest second propeller performance and the extracted second difference parameter is shown. Similarly, in step (G), an example of selecting the third model with the highest third propeller performance and generating three fourth models with a third difference based on the selected third model with the highest third propeller performance and the extracted third difference parameter is shown.

[0076] The number of each of the plurality of second models, the plurality of third models, and the plurality of fourth models is not particularly limited, but can be, for example, a model number of 2 to 50, 4 to 40, 6 to 30, or 8 to 20.

[0077] Since the plurality of models with differences are generated to have differences from the base model, they may have similar configurations to each other. Since the plurality of second models with a first difference are generated to have a first difference from the first model, they may have similar configurations to each other. Similarly, the plurality of third models with a second difference and the plurality of fourth models with a third difference may have similar configurations to each other.

[0078] If the propeller performance calculated by the fluid analysis simulation, for example, the second propeller performance, the third propeller performance, and the fourth propeller performance, is equal to or higher than a predetermined standard, it is determined as qualified; if it is less than the predetermined standard, it is determined as unqualified. The pass standard can be stored in the second storage device of the server. The processing device of the server can determine whether it is qualified or unqualified based on the input propeller performance and the pass standard stored in the second storage device. The determined pass / fail result can be output from the output unit of the server.

[0079] When a model with qualified propeller performance is obtained, for example, when the nth model including the second propeller performance, the third propeller performance, the fourth propeller performance, etc., which is the nth propeller performance, is qualified, a slicer drawing for a wire DED printer is created for the qualified nth model. n is an integer of 2 or more. That is, when the second propeller performance, the third propeller performance, the fourth propeller performance, ···, and the nth propeller performance corresponding to the second model, the third model, the fourth model, ···, and the nth model are all qualified, a slicer drawing for a wire DED printer is created for the qualified model.

[0080] If all the propeller performances are unqualified, until a model with qualified propeller performance is obtained, a plurality of models with similar shapes having differences are generated for models with high propeller performance calculated by the fluid analysis simulation, and a fluid analysis simulation regarding the propeller performance when the plurality of models with similar shapes are mounted is performed. For example, when the second propeller performance, the third propeller performance, and the fourth propeller performance are all unqualified, return to step (G) and repeat steps (G) to (I) until a model with qualified propeller performance is obtained.

[0081] The slicer drawing can include a 3D drawing and a drawing for a wire DED printer including a three-dimensional modeling process. The drawing for a wire DED printer can include the data of a 3D-CAD drawing.

[0082] The plurality of second models preferably have a configuration with a first difference from the first model in a second configuration including at least one of the shape of the toroidal propeller, the number of blades, the propeller length, the thickness, the bend, the surface properties of the blades, the voids, the diameter of the shaft, the length of the shaft, and the material. The plurality of second models can include data of 3D-CAD drawings including the configuration with the first difference. The second configuration may further include at least one of mass, density, and rigidity. The data of the 3D-CAD drawings can be converted into data for a wire DED printer by the second processing device.

[0083] The plurality of third models preferably have a configuration with a second difference from the second model with high second propeller performance in a third configuration including at least one of the shape of the toroidal propeller, the number of blades, the propeller length, the thickness, the bend, the surface properties of the blades, the voids, the diameter of the shaft, the length of the shaft, and the material. The plurality of third models can include data of 3D-CAD drawings including the configuration with the second difference. The third configuration may further include at least one of mass, density, and rigidity. The data of the 3D-CAD drawings can be converted into data for a wire DED printer by the second processing device.

[0084] The plurality of fourth models preferably have a configuration with a third difference from the third model with high third propeller performance in a fourth configuration including at least one of the shape of the toroidal propeller, the number of blades, the propeller length, the thickness, the bend, the surface properties of the blades, the voids, the diameter of the shaft, the length of the shaft, and the material. The plurality of fourth models can include data of 3D-CAD drawings including the configuration with the third difference. The fourth configuration may further include at least one of mass, density, and rigidity. The data of the 3D-CAD drawings can be converted into data for a wire DED printer by the second processing device.

[0085] The nth propeller performance, including the first propeller performance, the second propeller performance, the third propeller performance, and the fourth propeller performance, preferably includes evaluations for each item of the fuel consumption, vibration, noise, or a combination thereof of the mobility equipped with a toroidal propeller. The evaluation can be, for example, a stage display from 1 to 10 or a score display from 0 to 100 for each item. The evaluation may be, for example, a 10-stage evaluation for each item of fuel consumption, vibration, and noise, and a score obtained by adding the weighted coefficients for each item. The weighted coefficient can be a numerical value such as 1 to 10, and for example, if fuel consumption is the most important, the weighted coefficient of fuel consumption may be increased.

[0086] The determination of pass or fail of the nth propeller performance, including the second propeller performance, the third propeller performance, and the fourth propeller performance, is preferably made based on the evaluation. If the evaluation is above a predetermined pass criterion, it is considered a pass, and if it is below the pass criterion, it can be determined as a fail.

[0087] Preferably, generating the third model includes extracting the second difference parameters between the model with the highest second propeller performance among the plurality of second models and the first model, and generating a plurality of third models with differences based on the model with the highest second propeller performance and the extracted difference parameters.

[0088] Preferably, generating the fourth model includes extracting the third difference parameters between the model with the highest third propeller performance among the plurality of third models and the model with the highest second propeller performance among the plurality of second models, and generating a plurality of fourth models with a third difference based on the model with the highest third propeller performance and the extracted third difference parameters.

[0089] Preferably, creating a slicer drawing for a wire DED printer for the passed models includes creating a slicer drawing for a wire DED printer for the model with the highest propeller performance among the passed models.

[0090] Generating a plurality of second models includes the second processing device generating a plurality of second models with at least one parameter among the shape of the toroidal propeller, the number of blades, the propeller length, the thickness, the bend, the surface property of the blade, the void, the diameter of the shaft, the length of the shaft, and the material changed based on the first model stored in the second storage device.

[0091] Generating a plurality of third models includes the second processing device generating a plurality of third models with at least one parameter among the shape of the toroidal propeller, the number of blades, the propeller length, the thickness, the bend, the surface property of the blade, the void, the diameter of the shaft, the length of the shaft, and the material changed based on the second model with the highest second propeller performance stored in the second storage device and the extracted second differential parameters.

[0092] Generating a plurality of fourth models includes the second processing device generating a plurality of fourth models with at least one parameter among the shape of the toroidal propeller, the number of blades, the propeller length, the thickness, the bend, the surface property of the blade, the void, the diameter of the shaft, the length of the shaft, and the material changed based on the third model with the highest third propeller performance stored in the second storage device and the extracted third differential parameters.

[0093] The present disclosure also targets toroidal propellers for mobility with a diameter of 2000 mm or more.

[0094] The mobility is preferably a ship or an aircraft, more preferably a large ship or a giant ship.

[0095] The present disclosure also targets a manufacturing method of a toroidal propeller for mobility, including forming a toroidal propeller having a toroidal shape using a wire DED type 3D printer.

[0096] The present disclosure also relates to a method of creating a drawing of a toroidal propeller for mobility, (A) Generate a plurality of second models with a first difference based on the first model of the toroidal propeller. (B) Perform a fluid analysis simulation regarding the first propeller performance when the first model is mounted on the mobility and the second propeller performance when the plurality of generated second models are mounted. (C) Determine whether the second propeller performance calculated by the fluid analysis simulation is qualified or unqualified. (D) When all of the second propeller performances are unqualified, extract the second difference parameters between the model with the highest second propeller performance among the plurality of second models and the first model, and generate a plurality of third models with a second difference based on the model with the highest second propeller performance and the extracted second difference parameters. (E) Perform a fluid analysis simulation regarding the third propeller performance when the plurality of generated third models are mounted on the mobility. (F) Determine whether the third propeller performance calculated by the fluid analysis simulation is qualified or unqualified. (G) When all of the third propeller performances are unqualified, extract the third difference parameters between the model with the highest third propeller performance among the plurality of third models and the model with the highest second propeller performance among the plurality of second models, and generate a plurality of fourth models with a third difference based on the model with the highest third propeller performance and the extracted third difference parameters. (H) Perform a fluid analysis simulation regarding the fourth propeller performance when the plurality of generated fourth models are mounted on the mobility. (I) Determine whether the fourth propeller performance calculated by the fluid analysis simulation is qualified or unqualified. (J) When all of the fourth propeller performances are unqualified, repeat (G) to (I) until a model with qualified propeller performance is obtained, and (K)When a qualified n-th model with the n-th propeller performance is obtained, creating a slicer drawing for the 3D printer for the qualified n-th model, provided that n is an integer of 2 or more, and the method is directed to a drawing creation method.

[0097] The present disclosure also relates to a server in a drawing creation system for a toroidal propeller for mobility, (A) Second model generation means for generating a plurality of second models with a first difference based on the first model of the toroidal propeller stored in the storage device of the server, (B) First and second propeller performance analysis means for performing a fluid analysis simulation on the first propeller performance when the first model is mounted on the mobility and the second propeller performance when the plurality of generated second models are mounted, (C) Second propeller performance determination means for determining whether the second propeller performance calculated by the fluid analysis simulation is qualified or unqualified, (D) When all of the second propeller performances are unqualified, extracting a second difference parameter between the model with the highest second propeller performance among the plurality of second models and the first model, and generating a plurality of third models with a second difference based on the model with the highest second propeller performance and the extracted second difference parameter, (E) Third propeller performance analysis means for performing a fluid analysis simulation on the third propeller performance when the plurality of generated third models are mounted on the mobility, (F) Third propeller performance determination means for determining whether the third propeller performance calculated by the fluid analysis simulation is qualified or unqualified, (G) When all of the third propeller performances are unqualified, extracting a third difference parameter between the model with the highest third propeller performance among the plurality of third models and the model with the highest second propeller performance among the plurality of second models, and generating a plurality of fourth models with a third difference based on the model with the highest third propeller performance and the extracted third difference parameter, (H) Fourth propeller performance analysis means for performing a fluid analysis simulation regarding the fourth propeller performance when mounting the plurality of fourth models generated on the mobility, (I) Fourth propeller performance determination means for determining pass or fail of the fourth propeller performance calculated by the fluid analysis simulation, (J) Repetition means for repeating the above (G) to (I) until a model with qualified propeller performance is obtained when all of the fourth propeller performances are unqualified, and (K) Drawing creation means for creating a slicer drawing for the 3D printer for the qualified nth model when the nth model with qualified nth propeller performance is obtained, where n is an integer of 2 or more, The present disclosure is directed to a server including the above.

[0098] The present disclosure also relates to a server in a drawing creation system for a toroidal propeller for mobility, (A) Second model generation processing for generating a plurality of second models with a first difference based on the first model of the toroidal propeller stored in the storage device of the server, (B) First and second propeller performance analysis processing for performing a fluid analysis simulation regarding the first propeller performance when mounting the first model on the mobility and the second propeller performance when mounting the plurality of generated second models, (C) Second propeller performance determination processing for determining pass or fail of the second propeller performance calculated by the fluid analysis simulation, (D) When all of the second propeller performances are unqualified, extracting second difference parameters between the model with high second propeller performance among the plurality of second models and the first model, and generating a plurality of third models with a second difference based on the model with high second propeller performance and the extracted second difference parameters, (E) Third propeller performance analysis processing for performing a fluid analysis simulation regarding the third propeller performance when mounting the plurality of generated third models on the mobility, (F) A third propeller performance determination process for determining pass or fail of the third propeller performance calculated in the fluid analysis simulation. (G) When all of the third propeller performances are fails, extract a third difference parameter between the model with the highest third propeller performance among the plurality of third models and the model with the highest second propeller performance among the plurality of second models, and generate a plurality of fourth models with a third difference based on the model with the highest third propeller performance and the extracted third difference parameter in a fourth model generation process. (H) A fourth propeller performance analysis process for performing a fluid analysis simulation regarding the fourth propeller performance when the generated plurality of fourth models are mounted on the mobility. (I) A fourth propeller performance determination process for determining pass or fail of the fourth propeller performance calculated in the fluid analysis simulation. (J) When all of the fourth propeller performances are fails, a repetition process of repeating (G) to (I) until a model with a passing propeller performance is obtained, and (K) When an nth model with a passing nth propeller performance is obtained, a drawing creation process for creating a slicer drawing for the 3D printer for the passed nth model, where n is an integer of 2 or more. The program is targeted to execute the above. This program can be recorded in a storage device of a server, such as a medium like SSD, HDD, or a portable medium like USB, CD, DVD.

Example

[0099] (Example 1) A stainless steel shaft with a diameter of 127 mm was prepared. A wire DED type 3D printer (manufactured by Daihen, FD19) equipped with a robotic arm schematically shown in Fig. 1, a robot head connected to the robotic arm, an arc type heat source included in the robot head, and a wire feeding device was used. While heating and melting the stainless steel wire supplied from the wire feeding device with the heat source, the robot head was scanned to build up from the surface to the outer circumference of the prepared shaft, and two wing parts were merged to form an integrated toroidal shape wing, and the toroidal propeller shown in Figs. 11 and 12 with a diameter of 313 mm and an average pitch angle of 45 degrees was fabricated.

[0100] (Example 2) Using a 3D printer, a toroidal propeller with a diameter of 180 mm and an average pitch angle of 45 degrees was fabricated. Fig. 13 shows a model diagram of the fabricated toroidal propeller.

[0101] (Reference Example 1) Using a 3D printer, a conventional screw propeller with a diameter of 180 mm and an average pitch angle of 45 degrees was fabricated. Fig. 14 shows a model diagram of the fabricated screw propeller.

[0102] (Thrust Evaluation) The toroidal propeller fabricated in Example 2 and the screw propeller fabricated in Reference Example 1 were directly connected to a motor and installed on a movable rail respectively. By submerging the propeller in water and changing the amount of current flowing through the motor, the change in thrust was measured. Fig. 15 shows the thrust measurement results. The vertical axis is the tensile thrust (N), and the horizontal axis is the amount of current.

[0103] The toroidal propeller fabricated in Example 2 achieved a high thrust with respect to the screw propeller fabricated in Reference Example 1, exceeding it by 40% or more at a current of 3 A. Although the propeller sizes fabricated in Example 2 and Reference Example 1 are 180 mm, the difference between the Reynolds number for this size and that of a propeller with a diameter of 10 m or more, for example, a propeller with a diameter of 10 m, is negligibly small and substantially equal, so the engineering scaling law holds. Therefore, according to the engineering scaling law, this result can also be applied to toroidal propellers of large sizes.

Explanation of Signs

[0104] 100 Wire DED Printer 200 Server 300 Network 10 Production System 1 Robot Arm 2 Robot Heads 21 Heat Source 22 Wire 30 Heating and Melting Section 40 Substrate 50 Toroidal Propeller 52 Blades of Toroidal Propeller 54 Shaft of Toroidal Propeller 521 Two Blade Parts 54 Shaft of Toroidal Propeller 60 Conventional Propeller 61 Blades of Conventional Propeller 70 Holding Section

Claims

1. Equipped with a wire DED method 3D printer, A toroidal propeller having a toroidal shape can be formed by the 3D printer 、 The 3D printer includes a scanable robot arm, a robot head connected to the robot arm, a heat source included in the robot head, a holding part capable of holding a base material, and a wire supply device, The heat source is configured to heat and melt the wire supplied from the wire supply device, The robot head is configured to build up the wire heated and melted by the heat source on the base material held by the holding part while being scanned together with the robot arm, The base material is the shaft part of the toroidal propeller, The 3D printer builds up from the shaft part, which is the base material, toward the outer peripheral part of the toroidal propeller, and forms a toroidal-shaped blade in which two blade parts that are divided into two at the shaft part and joined together at the outer peripheral part are integrated, A manufacturing system for a toroidal propeller for mobility.

2. The 3D printer further includes a first storage device and a first processing device, Based on the model information of the toroidal propeller stored in the first storage device, the first processing device controls the robot arm and the robot head, The manufacturing system according to Claim 1.

3. Further includes a server having a second storage device and a second processing device, The following steps (a) to (f) are performed on the server: (a) Generating a plurality of models of similar shapes that differ from the basic model of the toroidal propeller stored in the second storage device, (b) Performing a fluid analysis simulation regarding the propeller performance when the basic model is mounted on the mobility and the propeller performance when the plurality of models of similar shapes are mounted, (c) Determining whether the propeller performance calculated by the fluid analysis simulation passes or fails, (d) When all the propeller performances fail, generating a plurality of models of similar shapes with differences for the models with high propeller performance calculated by the fluid analysis simulation until a model with qualified propeller performance is obtained, and performing a fluid analysis simulation regarding the propeller performance when the plurality of models of similar shapes with differences are mounted on the models with high propeller performance, (e) When a model with qualified propeller performance is obtained, creating a slicer drawing for the 3D printer for the qualified model, and (f) Forming the toroidal propeller using the 3D printer based on the slicer drawing (The manufacturing system according to claim 2, which causes the above to be executed.) (Claim 4) (The manufacturing system further includes a server having a second storage device and a second processing device, (The server is caused to perform the following steps (A) to (L): (A) Generating a plurality of second models with a first difference based on the first model of the toroidal propeller stored in the second storage device; (B) Performing a fluid analysis simulation regarding the first propeller performance when the first model is mounted on the mobility and the second propeller performance when the plurality of generated second models are mounted; (C) Determining whether the second propeller performance calculated in the fluid analysis simulation is qualified or unqualified; (D) When all of the second propeller performances are unqualified, extracting second difference parameters between the model with the highest second propeller performance among the plurality of second models and the first model, and generating a plurality of third models with a second difference based on the model with the highest second propeller performance and the extracted second difference parameters; (E) Performing a fluid analysis simulation regarding the third propeller performance when the plurality of generated third models are mounted on the mobility; (F) Determining whether the third propeller performance calculated in the fluid analysis simulation is qualified or unqualified; (G) When all of the third propeller performances are unqualified, extracting third difference parameters between the model with the highest third propeller performance among the plurality of third models and the model with the highest second propeller performance among the plurality of second models, and generating a plurality of fourth models with a third difference based on the model with the highest third propeller performance and the extracted third difference parameters; (H) Performing a fluid analysis simulation regarding the fourth propeller performance when the plurality of generated fourth models are mounted on the mobility; (I) Determining whether the fourth propeller performance calculated in the fluid analysis simulation is qualified or unqualified; (J) If all of the fourth propeller performances are unqualified, repeat (G) to (I) until a model with qualified propeller performance is obtained. (K) When an nth model with qualified nth propeller performance is obtained, create a slicer drawing for the 3D printer for the qualified nth model, where n is an integer of 2 or more, and (L) Based on the slicer drawing, form a toroidal propeller using the 3D printer The manufacturing system according to claim 2, which causes the above to be executed.

5. The first propeller performance, the second propeller performance, the third propeller performance, and the fourth propeller performance include an evaluation of the fuel consumption, vibration, noise, or a combination thereof of the mobility equipped with the toroidal propeller. The manufacturing system according to claim 4.

6. The determination of pass or fail of the second propeller performance, the third propeller performance, and the fourth propeller performance is performed based on the evaluation. The manufacturing system according to claim 5.

7. Generating the third model includes extracting second difference parameters between the model with the highest second propeller performance among the plurality of second models and the first model, and based on the model with the highest second propeller performance and the extracted second difference parameters, generating a plurality of third models with the second difference. The manufacturing system according to claim 4.

8. Generating the fourth model includes extracting third difference parameters between the model with the highest third propeller performance among the plurality of third models and the model with the highest second propeller performance among the plurality of second models, and based on the model with the highest third propeller performance and the extracted third difference parameters, generating a plurality of fourth models with the third difference. The manufacturing system according to claim 4.

9. Creating a slicer drawing for the 3D printer for the qualified model includes creating a slicer drawing for the 3D printer for the model with the highest propeller performance among the qualified models. The manufacturing system according to claim 4.

10. The toroidal propeller has a diameter of 2000 mm or more. The manufacturing system according to any one of claims 1 to 9.

11. The manufacturing system according to any one of claims 1 to 9, wherein the mobility is a ship or an aircraft.

12. The manufacturing system according to any one of claims 1 to 9, wherein the mobility is a large ship or a giant ship.

13. A method for manufacturing a toroidal propeller for mobility, which forms a toroidal propeller having a toroidal shape using a wire DED method 3D printer, wherein the 3D printer includes a scanable robot arm, a robot head connected to the robot arm, a heat source provided in the robot head, a holding part capable of holding a base material, and a wire supply device, the heat source is configured to heat and melt the wire supplied from the wire supply device, the robot head is configured to build up the wire heated and melted by the heat source on the base material held by the holding part while being scanned together with the robot arm, holding the base material, which is the shaft part of the toroidal propeller, in the holding part, and using the 3D printer to build up the wire heated and melted by the heat source from the shaft part, which is the base material, toward the outer peripheral part of the toroidal propeller, and joining two wing parts that are divided into two at the shaft part and merged at the outer peripheral part to form an integrated toroidal-shaped wing, A method for manufacturing a toroidal propeller for mobility, including the above steps.

14. A drawing creation method for a wire DED method 3D printer of a toroidal propeller for mobility, (A) generating a plurality of second models with a first difference based on a first model of the toroidal propeller, (B) performing a fluid analysis simulation regarding a first propeller performance when the first model is mounted on the mobility and a second propeller performance when the plurality of generated second models are mounted, (C) determining whether the second propeller performance calculated by the fluid analysis simulation is qualified or unqualified, (D) when all of the second propeller performances are unqualified, extracting a second difference parameter between a model with a high second propeller performance among the plurality of second models and the first model, and generating a plurality of third models with a second difference based on the model with a high second propeller performance and the extracted second difference parameter. (E) performing a fluid analysis simulation regarding a third propeller performance when the mobility is equipped with the plurality of generated third models; (F) determining pass or fail of the third propeller performance calculated by the fluid analysis simulation; (G) when all of the third propeller performances are fails, extracting a third difference parameter between a model with a high third propeller performance among the plurality of third models and a model with a high second propeller performance among the plurality of second models, and generating a plurality of fourth models with a third difference based on the model with a high third propeller performance and the extracted third difference parameter; (H) performing a fluid analysis simulation regarding a fourth propeller performance when the mobility is equipped with the plurality of generated fourth models; (I) determining pass or fail of the fourth propeller performance calculated by the fluid analysis simulation; (J) when all of the fourth propeller performances are fails, repeating (G) to (I) until a model with a passing propeller performance is obtained; and (K) when an nth model with a passing nth propeller performance is obtained, creating a slicer drawing for the 3D printer for the passed nth model, where n is an integer of 2 or more, A drawing creation method including the above.

15. A server in a drawing creation system for a 3D printer of a wire DED method for a toroidal propeller for mobility, (A) A second model generation means for generating a plurality of second models with a first difference based on the first model of the toroidal propeller stored in the storage device of the server; (B) First and second propeller performance analysis means for performing a fluid analysis simulation regarding a first propeller performance when the first model is mounted on the mobility and a second propeller performance when the plurality of generated second models are mounted; (C) A second propeller performance determination means for determining pass or fail of the second propeller performance calculated by the fluid analysis simulation; (D) When all of the second propeller performances are unqualified, extract the second difference parameter between the model with the highest second propeller performance among the plurality of second models and the first model, and based on the model with the highest second propeller performance and the extracted second difference parameter, generate a plurality of third models with a second difference, i.e., a third model generation means; (E) A third propeller performance analysis means for performing a fluid analysis simulation regarding the third propeller performance when the generated plurality of third models are mounted on the mobility; (F) A third propeller performance determination means for determining whether the third propeller performance calculated by the fluid analysis simulation is qualified or unqualified; (G) When all of the third propeller performances are unqualified, extract the third difference parameter between the model with the highest third propeller performance among the plurality of third models and the model with the highest second propeller performance among the plurality of second models, and based on the model with the highest third propeller performance and the extracted third difference parameter, generate a plurality of fourth models with a third difference, i.e., a fourth model generation means; (H) A fourth propeller performance analysis means for performing a fluid analysis simulation regarding the fourth propeller performance when the generated plurality of fourth models are mounted on the mobility; (I) A fourth propeller performance determination means for determining whether the fourth propeller performance calculated by the fluid analysis simulation is qualified or unqualified; (J) When all of the fourth propeller performances are unqualified, a repeating means for repeating (G) to (I) until a model with a qualified propeller performance is obtained, and (K) When an nth model with a qualified nth propeller performance is obtained, a drawing creation means for creating a slicer drawing for the 3D printer for the qualified nth model, where n is an integer of 2 or more; A server comprising the above.

16. In a server in a drawing creation system for a 3D printer using the wire DED method for a toroidal propeller for mobility, (A) A second model generation process for generating a plurality of second models with a first difference based on the first model of the toroidal propeller stored in the storage device of the server; (B) First and second propeller performance analysis processes that perform a fluid analysis simulation regarding the first propeller performance when the first model is mounted on the mobility and the second propeller performance when the plurality of generated second models are mounted, (C) A second propeller performance determination process that determines whether the second propeller performance calculated by the fluid analysis simulation is pass or fail, (D) When all of the second propeller performances are fail, extract the second difference parameter between the model with the highest second propeller performance among the plurality of second models and the first model, and based on the model with the highest second propeller performance and the extracted second difference parameter, a third model generation process that generates a plurality of third models with a second difference, (E) A third propeller performance analysis process that performs a fluid analysis simulation regarding the third propeller performance when the plurality of generated third models are mounted on the mobility, (F) A third propeller performance determination process that determines whether the third propeller performance calculated by the fluid analysis simulation is pass or fail, (G) When all of the third propeller performances are fail, extract the third difference parameter between the model with the highest third propeller performance among the plurality of third models and the model with the highest second propeller performance among the plurality of second models, and based on the model with the highest third propeller performance and the extracted third difference parameter, a fourth model generation process that generates a plurality of fourth models with a third difference, (H) A fourth propeller performance analysis process that performs a fluid analysis simulation regarding the fourth propeller performance when the plurality of generated fourth models are mounted on the mobility, (I) A fourth propeller performance determination process that determines whether the fourth propeller performance calculated by the fluid analysis simulation is pass or fail, (J) A repetition process that repeats (G) to (I) until a model with a pass propeller performance is obtained when all of the fourth propeller performances are fail, and (K) When a qualified nth model with a pass nth propeller performance is obtained, a drawing creation process that creates a slicer drawing for the 3D printer for the qualified nth model, provided that n is an integer of 2 or more, A program that causes the above to be executed.

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