Modeling planning support device

Abstract

To create a fine molding plan in which a deviation between the molding plan and an actual shape hardly occurs when laminating a plurality of weld beads.SOLUTION: A molding plan support device 15 comprises: a molding condition acquisition unit 31 which acquires locus information including a target position of a path of forming a weld bead and information on a welding condition of forming the weld bead; a shape prediction unit 33 which obtains a prediction shape in which the plurality of weld beads are laminated on the basis of the locus information and the information on the welding condition; a determination unit 35 which determines whether the target position of an other path excluding the target position of the path of forming the weld bead is included on the inner side of the contour of the prediction shape of any weld bead on a cross section orthogonal to the longitudinal direction of the weld bead; and a locus information change unit 37 which deletes the target position of the other path from the locus information when the target position of the other path is included on the inner side of the contour.SELECTED DRAWING: Figure 2

Description

[Technical Field]

[0001] The present invention relates to a modeling planning support device, a modeling planning support method, and a program. [Background technology]

[0002] In recent years, there has been an increasing need for parts manufacturing through additive manufacturing using 3D printers, and research and development is underway to commercialize additive manufacturing using metal materials. For example, Patent Document 1 discloses a three-dimensional printing device that forms a three-dimensional structure by layering weld beads formed by melting a metal welding wire. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Laid-Open No. 2015-160217 Summary of the Invention [Problem to be solved by the invention]

[0004] In general, in three-dimensional modeling, a bead formation trajectory is planned for each layer obtained by slicing a geometric model based on three-dimensional CAD data, and a torch is moved along the planned trajectory to form a bead layer. A desired object is then manufactured by stacking these bead layers. However, the shape of the object during stacking may deviate from the planned shape. In such cases, the target position of the planned bead formation trajectory (hereinafter also referred to as a "path") may be inappropriate for the actual shape of the layers already stacked. In manufacturing based on such a plan, there is a risk of the torch hitting the object or the gap between the object and the torch becoming too large, causing an arc start error, which could disrupt the continuation of the manufacturing process.

[0005] In the 3D printing device of Cited Document 1, when an overhang shape is formed by stacking an upper layer weld bead on a lower layer weld bead at an angle, the upper layer weld bead is formed at a position offset from the center line of the lower layer weld bead by an appropriate amount, thereby forming an overhang shape with a desired inclination angle. When printing a structure with such an overhang, the fine adjustment of the target position as described above is particularly difficult. Therefore, it is desirable to precisely adjust the printing plan of the object so that the target position does not mismatch with the actual shape.

[0006] Therefore, an object of the present invention is to provide a manufacturing planning support device, a manufacturing planning support method, and a program that can create a precise manufacturing plan that is less likely to deviate from the manufacturing plan and the actual shape when stacking multiple weld beads. [Means for solving the problem]

[0007] The present invention comprises the following configurations. (1) A manufacturing planning support device that determines manufacturing conditions for a model when manufacturing a model by repeatedly laminating weld beads formed by melting a filler material held by a manipulator using a heat source device, the device comprising: a forming condition acquisition unit that acquires trajectory information including a target position of a path that forms the weld bead and information on welding conditions that form the weld bead; a shape prediction unit that calculates a predicted shape of a plurality of the weld beads stacked on top of each other based on the trajectory information and the welding condition information; a determination unit that determines whether a target position of any pass other than a target position of a pass that forms the weld bead is included inside a contour of a predicted shape of any of the weld beads in a cross section perpendicular to a longitudinal direction of the weld bead; a trajectory information change unit that deletes the target position of the other path from the trajectory information when the target position of the other path is included inside the contour; A modeling planning support device comprising: (2) A modeling planning support method for determining modeling conditions for a model when manufacturing a model by repeatedly stacking weld beads formed by melting a filler material held by a manipulator using a heat source device, the method comprising: acquiring trajectory information including a target position of a path for forming the weld bead and information on welding conditions for forming the weld bead; A predicted shape of a plurality of the weld beads stacked on top of each other is obtained based on the trajectory information and the welding condition information. determining whether a target position of any pass other than a target position of a pass that forms the weld bead is included inside a contour of a predicted shape of any of the weld beads in a cross section perpendicular to a longitudinal direction of the weld bead; If the target position of the other path is included inside the contour, the target position of the other path is deleted from the trajectory information. A method for supporting design planning. (3) A program for executing a modeling planning support procedure for determining modeling conditions for a model when manufacturing a model by repeatedly stacking weld beads formed by melting a filler material held by a manipulator using a heat source device, the program comprising: On the computer, a step of acquiring trajectory information including a target position of a path for forming the weld bead and information on welding conditions for forming the weld bead; a step of determining a predicted shape of a plurality of the weld beads stacked on top of each other based on the trajectory information and the welding condition information; determining whether a target position of any pass other than a target position of a pass that forms the weld bead is included inside a contour of a predicted shape of any of the weld beads in a cross section perpendicular to a longitudinal direction of the weld bead; a step of deleting the target position of the other path from the trajectory information when the target position of the other path is included inside the contour; A program for executing. [Effects of the Invention]

[0008] According to the present invention, when stacking multiple weld beads, it is possible to create a precise manufacturing plan that is less likely to deviate from the manufacturing plan and the actual shape. [Brief explanation of the drawings]

[0009] [Figure 1] FIG. 1 is a schematic diagram showing the overall configuration of an additive manufacturing apparatus. [Figure 2] FIG. 2 is a functional block diagram of the modeling planning support apparatus. [Figure 3A] FIG. 3A is an explanatory diagram showing an example of a procedure for determining a path for forming a weld bead that constitutes a shaped object, in a cross section perpendicular to the longitudinal direction of the weld bead. [Figure 3B] FIG. 3B is an explanatory diagram showing an example of a procedure for determining a path for forming a weld bead that constitutes a shaped object, in a cross section perpendicular to the longitudinal direction of the weld bead. [Figure 3C] FIG. 3C is an explanatory diagram showing an example of a procedure for determining a path for forming a weld bead that constitutes a shaped object, in a cross section perpendicular to the longitudinal direction of the weld bead. [Figure 4] FIG. 4 is an explanatory diagram showing an example of a model that takes into consideration overlap between adjacent beads. [Figure 5] FIG. 5 is an explanatory diagram showing an example of a model that reproduces the shape of weld metal dripping down to the lower layer side. [Figure 6A] FIG. 6A is an explanatory diagram showing the target position of the path of the weld bead and the model shape. [Figure 6B] FIG. 6B is an explanatory diagram showing the results of optimizing the model shown in FIG. 6A. [Figure 7] FIG. 7 is a flowchart showing the steps of the modeling planning support method. [Figure 8A] FIG. 8A is an explanatory diagram showing each step of the manufacturing planning support method on a cross section perpendicular to the longitudinal direction of the weld bead. [Figure 8B] FIG. 8A is an explanatory diagram showing each step of the manufacturing planning support method on a cross section perpendicular to the longitudinal direction of the weld bead. [Figure 8C] FIG. 8C is an explanatory diagram showing each step of the manufacturing planning support method on a cross section perpendicular to the longitudinal direction of the weld bead. [Figure 8D] FIG. 8D is an explanatory diagram showing each step of the manufacturing planning support method on a cross section perpendicular to the longitudinal direction of the weld bead. [Figure 8E] FIG. 8E is an explanatory diagram showing each step of the manufacturing planning support method on a cross section perpendicular to the longitudinal direction of the weld bead. [Figure 8F] FIG. 8F is an explanatory diagram showing each step of the manufacturing planning support method on a cross section perpendicular to the longitudinal direction of the weld bead. [Figure 8G] FIG. 8G is an explanatory diagram showing each step of the manufacturing planning support method on a cross section perpendicular to the longitudinal direction of the weld bead. [Figure 8H] FIG. 8H is an explanatory diagram showing each step of the manufacturing planning support method on a cross section perpendicular to the longitudinal direction of the weld bead. [Figure 8I] FIG. 8I is an explanatory diagram showing each step of the manufacturing planning support method on a cross section perpendicular to the longitudinal direction of the weld bead. [Figure 9A] FIG. 9A is an explanatory diagram showing a criterion by which the determination unit determines the target position in the lamination direction of the weld beads. [Figure 9B] FIG. 9B is an explanatory diagram showing a criterion by which the determination unit determines the target position in relation to the arrangement direction of the weld beads. [Figure 10A] FIG. 10A is a reference diagram showing an example in which the target position is deleted when a plurality of weld beads are formed in parallel. [Figure 10B] FIG. 10B is a reference diagram showing an example in which the target position is deleted when a plurality of weld beads are formed in parallel. [Figure 10C] FIG. 10C is a reference diagram showing an example in which the target position is deleted when a plurality of weld beads are formed in parallel. [Figure 11A] FIG. 11A is an explanatory diagram showing another example in which the target position is eliminated when a plurality of weld beads are formed in parallel. [Figure 11B] FIG. 11B is an explanatory diagram showing another example in which the target position is eliminated when a plurality of weld beads are formed in parallel. [Figure 11C]FIG. 11C is an explanatory diagram showing another example in which the target position is eliminated when a plurality of weld beads are formed in parallel. [Figure 11D] FIG. 11D is an explanatory diagram showing another example in which the target position is eliminated when a plurality of weld beads are formed in parallel. [Figure 12A] FIG. 12A is a reference diagram showing another example in which the target position is eliminated when a plurality of weld beads are formed in parallel. [Figure 12B] FIG. 12B is a reference diagram showing another example in which the target position is eliminated when a plurality of weld beads are formed in parallel. [Figure 12C] FIG. 12C is a reference diagram showing another example in which the target position is eliminated when a plurality of weld beads are formed in parallel. [Figure 13A] FIG. 13A is an explanatory diagram showing another example in which the target position is eliminated when a plurality of weld beads are formed in parallel. [Figure 13B] FIG. 13B is an explanatory diagram showing another example in which the target position is eliminated when a plurality of weld beads are formed in parallel. [Figure 13C] FIG. 13C is an explanatory diagram showing another example in which the target position is eliminated when a plurality of weld beads are formed in parallel. [Figure 13D] FIG. 13D is an explanatory diagram showing another example in which the target position is eliminated when a plurality of weld beads are formed in parallel. DETAILED DESCRIPTION OF THE INVENTION

[0010] Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. The additive manufacturing device described here uses a heat source device to melt a filler material (welding wire) held by a manipulator to form a weld bead based on a predetermined manufacturing plan, and then repeatedly stacks the formed weld beads into a desired shape to manufacture a molded object made of stacked weld beads. When manufacturing a molded object using such an additive manufacturing device, the manufacturing plan support device determines manufacturing conditions such as the target position (trajectory) of the weld bead path and welding conditions, and supports the creation of the above-mentioned manufacturing plan.

[0011] <Configuration of additive manufacturing equipment> An example of the configuration of an additive manufacturing apparatus that operates based on a manufacturing plan created by the above-described manufacturing plan support apparatus will be described. FIG. 1 is a schematic diagram showing the overall configuration of an additive manufacturing apparatus. The additive manufacturing apparatus 100 includes a manufacturing control unit 11 and a manufacturing unit 13. The manufacturing planning support device 15 may be connected to the manufacturing control unit 11 to form a part of the additive manufacturing apparatus 100, or may be provided separately from the additive manufacturing apparatus 100 and connected via communication such as a network or a storage medium.

[0012] The molding unit 13 includes a manipulator 17, a filler metal supply unit 19, a manipulator control unit 21, and a heat source control unit 23.

[0013] The manipulator control unit 21 controls the manipulator 17 and the heat source control unit 23. A controller (not shown) is connected to the manipulator control unit 21, and any operation from the manipulator control unit 21 can be instructed by an operator via the controller.

[0014] The manipulator 17 is, for example, an articulated robot, and a torch 25 attached to the tip shaft supports the filler material M so that it can be continuously supplied. The torch 25 holds the filler material M protruding from the tip. The position and posture of the torch 25 can be set arbitrarily in three dimensions within the range of the degrees of freedom of the robot arm constituting the manipulator 17. The manipulator 17 preferably has six or more degrees of freedom, and is preferably one that can arbitrarily change the axial direction of the heat source at the tip. The manipulator 17 may be in various forms, such as a four- or more-axis articulated robot as shown in FIG. 1, or a robot equipped with angle adjustment mechanisms on two or more orthogonal axes.

[0015] The torch 25 has a shield nozzle (not shown), through which shielding gas is supplied. The shielding gas blocks the atmosphere and prevents oxidation and nitridation of the molten metal during welding, thereby suppressing welding defects. The arc welding method used in this configuration may be either a consumable electrode type such as shielded metal arc welding or carbon dioxide gas arc welding, or a non-consumable electrode type such as TIG (Tungsten Inert Gas) welding or plasma arc welding, and is selected appropriately depending on the object to be formed. Here, gas metal arc welding will be used as an example. In the case of a consumable electrode type, a contact tip is disposed inside the shield nozzle, and a filler material M to which current is supplied is held by the contact tip. The torch 25 holds the filler material M and generates an arc from the tip of the filler material M in a shielding gas atmosphere.

[0016] The filler material supply unit 19 supplies the filler material M toward the torch 25. The filler material supply unit 19 includes a reel 19a around which the filler material M is wound, and a payout mechanism 19b that pays out the filler material M from the reel 19a. The filler material M is fed to the torch 25 by the payout mechanism 19b while being sent in the forward or reverse direction as needed. The payout mechanism 19b is not limited to a push type that is arranged on the filler material supply unit 19 side and pushes out the filler material M, but may also be a pull type or a push-pull type that is arranged on a robot arm or the like.

[0017] The heat source control unit 23 is a welding power source that supplies the power required for welding by the manipulator 17. The heat source control unit 23 adjusts the welding current and welding voltage supplied when forming a bead by melting and solidifying the filler material M. In addition, the filler material supply speed of the filler material supply unit 19 is adjusted in conjunction with the welding conditions such as the welding current and welding voltage set by the heat source control unit 23.

[0018] The heat source for melting the filler material M is not limited to the arc described above. Other heat sources may be used, such as a heating method that combines an arc and a laser, a heating method that uses plasma, or a heating method that uses an electron beam or a laser. Heating with an electron beam or a laser allows for more precise control of the amount of heat, which can maintain the state of the formed bead more appropriately and contribute to further improving the quality of the laminated structure. The material of the filler material M is also not particularly limited. The type of filler material M used may vary depending on the characteristics of the object W, such as mild steel, high-tensile steel, aluminum, aluminum alloy, nickel, or nickel-based alloy.

[0019] The forming control unit 11 controls the above-mentioned units in an integrated manner.

[0020] The additive manufacturing apparatus 100 configured as described above operates in accordance with a manufacturing program created based on a manufacturing plan for the object W. The manufacturing program is composed of a large number of command codes and is created based on an appropriate algorithm depending on various conditions, such as the shape, material, and heat input of the object. According to this manufacturing program, the torch 25 is moved to melt and solidify the supplied filler material M, thereby forming a linear weld bead B, which is a molten solid of the filler material M, on the base 27. That is, the manipulator control unit 21 drives the manipulator 17 and the heat source control unit 23 based on a predetermined program provided by the manufacturing control unit 11. In response to a command from the manipulator control unit 21, the manipulator 17 moves the torch 25 while melting the filler material M with an arc to form the weld bead B. By sequentially forming and stacking the weld beads B in this manner, a desired object W is obtained.

[0021] <Configuration of the modeling planning support device> 2 is a functional block diagram of the modeling planning support device 15. The modeling planning support device 15 includes a modeling condition acquisition unit 31, a shape prediction unit 33, a determination unit 35, a trajectory information change unit 37, and a modeling condition update unit 39. Details of each unit will be described later, but the general functions are as follows.

[0022] The modeling condition acquisition unit 31 acquires trajectory information including a target position of a path for forming a weld bead, and modeling conditions including information on welding conditions for forming a weld bead. The modeling conditions may be extracted from a modeling plan or a modeling program created corresponding to the model. Shape prediction unit 33 determines a predicted shape of a plurality of weld beads stacked on top of each other based on the acquired trajectory information and welding condition information. That is, it determines the target position of the pass that will form the weld bead and the predicted shape of the weld bead formed at the target position. Determination unit 35 determines whether the target positions of passes other than the target position of the pass of any weld bead are included inside the outline of the predicted shape of any weld bead in a cross section perpendicular to the longitudinal direction of the weld bead. If the target position of the other path is included inside the contour, the trajectory information change unit 37 deletes the information on the target position of the other path from the acquired trajectory information. When the determination unit 35 determines that the target position of another pass is included, the modeling condition update unit 39 updates the modeling conditions by changing the number of passes or the welding conditions.

[0023] The modeling plan corrected based on the updated modeling conditions is output to the modeling control unit 11. The modeling control unit 11 controls the drive of the modeling unit 13 based on this modeling plan, thereby making it possible to obtain a modeled object with a more appropriate shape.

[0024] The above-mentioned modeling planning support device 15 is configured by hardware using an information processing device such as a PC (Personal Computer). Each function of the modeling planning support device 15 is realized by a control unit (not shown) reading and executing a program having a specific function stored in a storage device (not shown). Examples of the control unit include a processor such as a CPU (Central Processing Unit) or an MPU (Micro Processor Unit), or a dedicated circuit. Examples of the storage device include a memory such as a RAM (Random Access Memory) which is a volatile storage area, a ROM (Read Only Memory) which is a non-volatile storage area, a hard disk drive (HDD), a solid state drive (SSD), etc.

[0025] In addition to the above-described configuration, the modeling planning support device 15 may be another computer connected to the modeling control unit 11 from a remote location via a network or the like, as described above.

[0026] <Design plans and models> 3A, 3B, and 3C are explanatory diagrams showing an example of a procedure for determining a formation path of a weld bead that constitutes a laminate, in a cross section perpendicular to the longitudinal direction of the weld bead. First, the shape of the object is obtained from shape data such as CAD data. Then, as shown in Fig. 3A, the target shape So of the object to be produced is sliced ​​into multiple layers L1, L2, L3, and L4 according to the bead height H of a predetermined weld bead. The number of divided layers and the bead height can be set arbitrarily, and the specific method for dividing the shape is not particularly limited, and any known method can be used.

[0027] Each of the divided layers L1, L2, L3, and L4 is divided into a plurality of rectangular bead models BM0 so as to correspond to the cross-sectional shape of the weld bead, as shown in Figure 3B. As a result, each of the layers L1, L2, L3, and L4 is divided into a plurality of rectangular bead models BM0. When dividing the rectangular bead models BM0, conditions may be specified, such as making the bead cross-sectional area in a cross section orthogonal to the bead longitudinal direction constant for each rectangular bead model BM0.

[0028] The divided rectangular bead models BM0 are fitted to a semicircular shape, which is a simple geometric figure shown as an example, as shown in Figure 3C. Here, each rectangular bead model BM0 is changed to a semicircular bead model BM having a base 41 and an arc 43, and which is close to the shape of an actual weld bead. The shape of the fitted bead model BM is arbitrary, but if the relationship between the welding conditions and the bead shape is managed in advance as a database, a model of an appropriate shape may be set by referring to the database.

[0029] Then, for example, the midpoint of the base 41 is set as the target position P of the weld bead as a representative position of the obtained semicircular bead model BM. The target position P, which is the midpoint, is a line that forms a group of points along the longitudinal direction of the bead model BM that continues in the depth direction of FIG. 3C, and this line becomes the path PS for forming the weld bead. A path PS is set for each of the multiple bead models BM. The path PS includes information on the target position for forming the weld bead and information on the planned height (bead height H) of the weld bead. Note that in addition to finding the path PS by fitting the bead model BM to the entire printing shape, it is also possible to find the path PS for the entire printing shape by duplicating the path PS that partially generates a part of the printing shape in parallel.

[0030] The modeling condition obtaining unit 31 shown in FIG. 2 may obtain the information on the path PS by performing the calculation as described above, or may read information obtained by another computer or the like.

[0031] Here, examples of other model shapes of the bead model BM will be described. FIG. 4 is an explanatory diagram showing an example of a model that takes into account the overlap between adjacent beads. FIG. 4 shows three model shapes in a cross section perpendicular to the longitudinal direction of the weld bead. For each model, the cross-sectional shape of model BM1 of the reference pass PS1 is a trapezoid. Model BM2 of pass PS2 is adjacent to model BM1, and model BM3 of pass PS3 is adjacent to model BM2. Models BM2 and BM3 partially overlap the model located on the left side of FIG. 4. Specifically, models BM2 and BM3 basically have the same trapezoidal shape as model BM1, but the base of the trapezoid is tilted by rotating it clockwise a predetermined angle around one end of the base of the trapezoid opposite to model BM1 while maintaining the cross-sectional shape. The portion of model BM2 that overlaps with model BM1 is considered to be the region of model BM1, and the lower region of model BM2 that is not included in model BM1 is included in the region of model BM2. Similarly, the area where model BM3 overlaps with model BM2 is defined as the area of ​​model BM2, and the area below model BM3 that is not included in model BM2 is included in the area of ​​model BM3.

[0032] As a result, the shape of model BM2 becomes a polygonal shape (pentagon) that is close to one of the hypotenuses of model BM1, and the shape of model BM3 becomes a polygonal shape (pentagon) that is close to one of the hypotenuses of model BM2. In this way, each of BM1, BM2, and BM3 becomes a shape that more closely resembles the cross-sectional shape of an actual weld bead.

[0033] Fig. 5 is an explanatory diagram showing an example of a model that reproduces the shape of weld metal sagging to the lower layer side. Fig. 5 also shows the model shape in a cross section perpendicular to the longitudinal direction of the weld bead. Among model BM1, which has a trapezoidal cross section and models BM2, BM3, . . . , BMn (n is an integer) layered above model BM1, the upper trapezoidal bead models BM2, BM3, . . . , BMn have downwardly extending hanging portions 47a, 47b added to both ends of base 45. The cross-sectional shape of hanging portions 47a, 47b is a triangle with one side being the end of base 45, and the shape and area are set according to the welding conditions and trajectory information (path) of the weld bead described above. Hanging portions 47a and 47b may have the same shape or different shapes. Furthermore, hanging portions 47a, 47b may be provided in pairs or may be provided at only one end of base 45 of the trapezoidal model.

[0034] By setting models BM2, BM3, ..., BMn with sagging portions 47a, 47b as bead models for forming planning, the bead height of the weld bead is affected by the sagging of molten metal that occurs in the weld bead. This makes it easier to match the predicted shape of the weld bead contour with the actual shape, even under conditions where the molten metal of the weld bead is likely to sag, such as in overhanging portions.

[0035] The shape of the model can also be determined according to welding conditions, such as welding current, welding voltage, torch movement speed (rod running speed), and filler metal feed speed.

[0036] For example, the bead height H may be calculated from equation (1), and the bead width LW may be calculated from equation (2). H = C1 + C2 W f +C3T s +C4W f 2 +C5T s 2 +C6W f T s ...Equation (1) LW=D1+D2W f +D3T s +D4W f 2 +D5T s 2 +D6W f Ts ...Equation (2) T s : Torch movement speed W f :Filler feed rate C1~C6: Coefficients D1 to D6: Coefficients

[0037] For example, the model shape may be determined by searching for a model shape that is closest to the set welding conditions from a database that stores welding conditions in association with parameters such as the weld cross-sectional area, bead height, bead width, etc. Alternatively, an approximation formula may be created based on the database, and the model shape may be determined using the approximation formula.

[0038] <Modeling planning support method> Next, the procedure of the modeling planning support method by the modeling planning support device 15 will be described. 6A is an explanatory diagram showing the target positions of the weld bead path and the model shapes. The target positions calculated based on the manufacturing plan are P1-a, P1-b, and P1-c for the first layer on base 27, P2-a, P2-b, and P2-c for the second layer, and P3-a, P3-b, and P3-c for the third layer. When the model shapes of the weld bead calculated for each target position according to the welding conditions are BM1a, BM1b, and BM1c for the first layer, BM2a, BM2b, and BM2c for the second layer, and BM3a, BM3b, and BM3c for the third layer, respectively. The stack height of each of these model shapes may not match the height of the target position corresponding to the target shape.

[0039] In this case, the manufacturing planning support method deletes the target position of the second layer and its model to correct the excessive layer height so that an appropriate weld bead can be formed at the target position based on the manufacturing plan.

[0040] Fig. 6B is an explanatory diagram showing the results of optimizing the model shown in Fig. 6A. As shown in Fig. 6B, by deleting the target position of the second layer and its model, the stacking height of the entire model is reduced, making it possible to form a weld bead that is closer to the manufacturing plan.

[0041] The present modeling planning support method is generally implemented by carrying out the above-described procedure, and will be described in detail below. FIG. 7 is a flowchart showing the steps of the modeling planning support method. 2 acquires information on the trajectory of the object to be formed and information on the forming conditions, including the welding conditions (S1). This information on the forming conditions may be generated by a predetermined algorithm, or may be extracted from information on an already created forming plan or a forming program.

[0042] 8A to 8I are explanatory diagrams showing each step of the manufacturing planning support method on a cross section perpendicular to the longitudinal direction of the weld bead. The shape of the object to be manufactured here is a target shape 51 shown in FIG. 8A, and this target shape 51 is decomposed into five layers and consists of models BM1 to BM5. The stacking direction SD of each of the models BM1 to BM5 is inclined from the vertical direction, but this inclination angle is arbitrary.

[0043] 8A, shape prediction unit 33 determines target positions P1-P5 of the paths of the weld beads to be formed corresponding to each of models BM1-BM5 of target shape 51 based on the acquired trajectory information and welding condition information, as shown in Fig. 8B, and predicts the shapes of weld beads B1-B5 to be formed at each target position P1-P5 (S2). In this case, the predicted result of weld bead B5 greatly exceeds the layer height of model BM5, which can be said to be an inappropriate layering state.

[0044] To eliminate this inappropriate layering state, determination unit 35 compares the predicted shape with the target position (path generation position) (S3). First, as shown in FIG. 8B, it is determined whether any target positions other than target position P1 of weld bead B1 are included inside the contour of the predicted shape of any weld bead, in this case, weld bead B1 of the first layer (S4). In this case, in addition to target position P1, target position P2 is included inside the contour of the predicted shape of weld bead B1. In other words, there are multiple path generation positions inside the contour of the predicted shape.

[0045] Therefore, trajectory information change unit 37 deletes and moves the path generation positions (S5). Specifically, as shown in Fig. 8C, target position P2 is deleted. Also, target position P3 of the third layer is moved parallel to the lamination direction SD of the weld beads to a position where it intersects with the outline of the predicted shape of weld bead B1 of the first layer.

[0046] Then, as shown in FIG. 8D, shape prediction unit 33 again predicts the shape of weld bead B3 to be formed at target position P3 after the movement under the welding conditions described above. Determination unit 35 determines whether any other target positions, other than target position P3, are included inside the outline of the predicted shape of weld bead B3 (S4). In this case, since no other target positions are included and there is an upper layer, processing continues (S6). That is, as shown in FIG. 8E, target position P4 of the fourth layer, which is the upper layer, is moved along stacking direction SD to a position where it intersects with the outline of weld bead B3 predicted as described above (S7).

[0047] This process is repeated up to the top layer. In FIG. 8F, the shape of weld bead B4 to be formed under the welding conditions described above at target position P4 after the movement is again predicted. Then, after confirming that no other path generation positions exist inside the outline of the predicted shape of weld bead B4, target position P5 of the fifth layer, which is the upper layer, is moved as shown in FIG. 8G. Furthermore, as shown in FIG. 8H, the shape of weld bead B5 to be formed under the welding conditions described above at target position P5 after the movement is again predicted. Then, it is confirmed that no other path generation positions exist inside the outline of the predicted shape of weld bead B5.

[0048] Through the above process, the originally planned five-layer structure is changed to the four-layer structure shown in Fig. 8H. As a result, the predicted shape of the weld beads stacked becomes a shape that is closer to target shape 51 than Fig. 8B.

[0049] Furthermore, as shown in Figure 8I, it is preferable to fine-tune the positions of each target position P1, P3, P4, and P5 so that there is neither an excess nor a deficiency of weld beads when forming the changed target shape 51. Generally, target shape 51 is set to a shape that adds excess material to the final product shape. The top weld bead B5 shown in Figure 8I includes the upper region of target shape 51 (the part of model BM5) to the extent that the product shape can be cut out from target shape 51.

[0050] The printing condition updating unit 39 updates the printing plan based on the printing conditions initially acquired by the printing condition acquisition unit 31 to a printing plan in which the target positions P1, P3, P4, and P5 shown in Fig. 8H or 8I are used as pass generation positions. In this way, when the shape of an object determined from CAD data or the like is generated by dividing it into layers, even if parameters such as the height of each layer and the pass interval do not match the set welding conditions, the target shape of the object can be reproduced with high accuracy by adjusting the number of divided layers and the number of passes.

[0051] In the above procedure, the path is changed without changing the welding conditions, but the welding conditions may be changed together with the path change. In this case, by changing the welding conditions according to various lamination situations, various bead shape parameters such as bead width and bead height can be adjusted, and the lamination shape can be more easily approximated to the target shape 51.

[0052] Then, based on the trajectory information of the updated modeling conditions and the information of the welding conditions, it is preferable to repeatedly perform the following: calculation of a predicted shape by the shape prediction unit 33; determination of whether the target positions of other passes are included by the determination unit 35; change of the trajectory information by the trajectory information change unit 37; and update of the modeling conditions by the modeling condition update unit 39. By repeatedly updating the modeling conditions, it is possible to automatically and widely search for the optimal number of passes, number of layers, and welding conditions.

[0053] When the determining unit 35 determines whether a target position (path generation position) of another layer exists inside the contour of the predicted shape, it is not limited to determining whether the position is inside or outside the contour position as a boundary. 9A is an explanatory diagram showing criteria used by determination unit 35 to determine the target position in stacking direction SD of the weld bead. A target position P2 of a second-layer weld bead is included inside the outline of the predicted shape of weld bead B1 formed at target position P1 of the first-layer weld bead. In this case, the weld bead may be determined to be inside when the length between target position P2 and the outline along stacking direction SD, i.e., the penetration amount Dh of target position P2 into the predicted shape of weld bead B1, is equal to or greater than a predetermined value or within a predetermined range.

[0054] For example, if target position P2 is located inside the predicted shape but very close to the contour, deleting target position P2 will not have a significant effect on the layering state of the weld bead, and will instead increase the deviation from the target shape. In this case, target position P2 is not considered to be inside the contour. This prevents excessive deletion of paths and eliminates the unnecessary process of recalculating the predicted shape of the weld bead. This improves processing speed.

[0055] The above-mentioned matters are not limited to the stacking direction of the weld beads, but can also be implemented in the direction in which the weld beads are arranged. FIG. 9B is an explanatory diagram showing criteria used by determination unit 35 to determine the target position with respect to the alignment direction LD of the weld beads. Here, when forming multiple rows of weld beads in the first layer along the alignment direction LD, the target position of the first weld bead B1-1 is defined as P1-1, the target position of the second weld bead B1-2 is defined as P1-2, and the target position of the third weld bead P1-3 is defined as P1-3. The target position P1-2 in the second row is included within the contour of the predicted shape of weld bead B1-1. In this case, the length along the alignment direction LD between the target position P2 and the contour, i.e., the penetration amount Dw of the target position P2 into the predicted shape of weld bead B1, is defined as Dw. It may be determined that the target position P2 is inside the contour when the penetration amount Dw is equal to or greater than a predetermined value or within a predetermined range. In this case, as with the stacking direction SD described above, unnecessary calculations can be omitted, improving processing speed.

[0056] <Other examples of adjusting the path generation position> The adjustment of the target position (path generation position) of the weld bead as described above may result in changes in the lamination results depending on the processing order. 10A to 10C are reference diagrams showing an example in which the target position is eliminated when a plurality of weld beads are formed in parallel. As shown in FIG. 10A , when weld beads are formed in recess 27a of base 27 in the order of target positions P1, P2, P3, and P4, the inside of the outline of the predicted shape of weld bead B1 includes target position P3 in addition to target position P1. Similarly, the inside of the outline of the predicted shape of weld bead B2 includes target position P4 in addition to target position P2. Therefore, as shown in FIG. 10B , if target positions P3 and P4 are deleted according to the procedure described above, weld beads B1 and B2 remain, and weld beads B3 and B4 are both deleted. As a result, as shown in FIG. 10C , even if target positions P1 and P2 are adjusted to be closer to the center of the bead width, unwelded region 53 remains between weld beads B1 and B2.

[0057] In this case, the occurrence of unwelded areas 53 can be prevented by increasing the number of passes. 11A to 11D are explanatory diagrams showing another example in which a target position is deleted when forming multiple weld beads in parallel. Here, the number of passes is increased by one compared to the example shown in FIG. 10A. As shown in FIG. 11A, when weld beads are formed in recess 27a of base 27 in the order of target positions P1, P2, P3, P4, and P5, the inside of the outline of the predicted shape of weld bead B1 includes target position P3 in addition to target position P1. Therefore, as shown in FIG. 11B, target position P3 is deleted according to the procedure described above. Next, as shown in FIG. 11C, target position P4 is deleted in a similar manner. As a result, weld beads B1, B2, and B5 remain, and weld beads B3 and B4 are deleted. Then, as shown in FIG. 11D, the positions of target positions P1, P2, and P5 are adjusted so that they are each closer to the center of the bead width. As a result, the recess 27a of the base 27 is filled with weld beads B1, B2, and B5 without leaving any gaps.

[0058] As mentioned above, if an appropriate solution does not exist when the number of passes is set to 4, changing the number of passes will result in an appropriate solution, as shown in Figure 11D. The number of passes can also be adjusted while taking into account the impact of removing passes. This allows the remaining volume of the required weld bead to be determined, and the appropriate bead shape can be generated sequentially by fine-tuning the welding conditions. The appropriate number of passes can be determined by repeatedly performing the target position adjustment procedure described above, which allows the most efficient number of passes and number of layers to be determined, and the appropriate welding conditions to be automatically searched for.

[0059] 12A to 12C are reference diagrams showing another example in which the target position is eliminated when forming a plurality of weld beads in parallel. As shown in FIG. 12A , when weld beads are formed in recess 27a of base 27 in the order of target positions P1, P2, P3, P4, and P5, the inside of the outline of the predicted shape of weld bead B1 includes target position P3 in addition to target position P1. Similarly, the inside of the outline of the predicted shape of weld bead B2 includes target position P4 in addition to target position P2. Therefore, as shown in FIG. 12B , if target positions P3 and P4 are deleted simultaneously according to the procedure described above, weld beads B1, B2, and B3 remain, and weld beads B4 and B5 are also deleted. Note that weld bead B3 is retained without being deleted because target position P5 is included within the outline of the predicted shape. Then, as shown in FIG. 12C , even if target positions P5 and P2 are adjusted to be closer to the center of the bead width, unwelded region 53 remains between weld beads B3 and B2. In this way, if the number of passes is adjusted after the predicted shape of the weld bead is calculated all at once, excessive passes will be deleted, and the weld bead filling the center area will disappear.

[0060] In this case, it is preferable to determine whether or not to delete the path generation position each time a predicted shape of one weld bead is generated. 13A to 13D are explanatory diagrams showing another example in which target positions are deleted when forming multiple weld beads in parallel. As shown in FIG. 13A, when weld beads are formed in recess 27a of base 27 in the order of target positions P1, P2, P3, P4, and P5, the inside of the outline of the predicted shape of weld bead B1 includes target position P3 in addition to target position P1. Therefore, as shown in FIG. 13B, target position P3 is deleted according to the procedure described above. Next, as shown in FIG. 13C, target position P4 is similarly deleted. As a result, weld beads B1, B2, and B5 remain, and weld beads B3 and B4 are deleted. Then, as shown in FIG. 13D, the positions of target positions P1, P2, and P5 are adjusted to be closer to the center of the bead width. This allows weld beads B1, B2, and B5 to fill recess 27a of base 27 without gaps.

[0061] In this way, by changing the timing of path deletion, an appropriate solution such as that shown in Fig. 13D can be obtained. In this case, too, the remaining volume of the required weld bead can be determined, and an appropriate bead shape can be generated sequentially after fine-tuning the welding conditions.

[0062] Furthermore, by moving the target position of the path adjacent to the target position of the deleted path closer to the position where it intersects with the contour of the predicted shape, it is possible to avoid a situation where the target position and the position of the bead surface become separated and the weld bead is not formed as expected, and it is possible to suppress missed swings of the manipulator and interference between the manipulator and other parts.

[0063] As such, the present invention is not limited to the above-described embodiments, and the present invention also contemplates the mutual combination of the various components of the embodiments, as well as modifications and applications by those skilled in the art based on the description in the specification and well-known techniques, and these modifications and applications are included in the scope of protection sought.

[0064] As described above, the present specification discloses the following: (1) A manufacturing planning support device that determines manufacturing conditions for a model when manufacturing a model by repeatedly laminating weld beads formed by melting a filler material held by a manipulator using a heat source device, the device comprising: a forming condition acquisition unit that acquires trajectory information including a target position of a path that forms the weld bead and information on welding conditions that form the weld bead; a shape prediction unit that calculates a predicted shape of a plurality of the weld beads stacked on top of each other based on the trajectory information and the welding condition information; a determination unit that determines whether a target position of any pass other than a target position of a pass that forms the weld bead is included inside a contour of a predicted shape of any of the weld beads in a cross section perpendicular to a longitudinal direction of the weld bead; a trajectory information change unit that deletes the target position of the other path from the trajectory information when the target position of the other path is included inside the contour; A modeling planning support device comprising: According to this manufacturing planning support device, the shape prediction unit calculates a predicted shape of the weld bead based on the trajectory information and welding condition information acquired by the manufacturing condition acquisition unit, and if the determination unit determines that the target positions of other passes are included inside the contour of the predicted shape, the trajectory information change unit deletes the target positions of the other passes from the trajectory information. As a result, even if the predicted shape of the layered weld bead does not match the target shape, the number of layers and the number of passes can be automatically adjusted to obtain an appropriate layered shape.

[0065] (2) The object-forming planning support device according to (1), wherein the determination unit determines whether the target position of the other path is included in the contour, depending on an amount that the target position of the other path bites into the inside of the contour. According to this modeling planning support device, when the target position of another path is near the contour, excessive deletion of paths is suppressed, thereby reducing the amount of calculation processing.

[0066] (3) The molding planning support device according to (1) or (2), wherein the shape prediction unit predicts the predicted shape and the determination unit determines whether the target position of the other path is included for each path. This modeling planning support device performs prediction and judgment for each pass sequentially, which prevents unnecessary generation of predicted shapes. Also, compared to generating predicted shapes all at once, it prevents unintentional deletion of weld beads and enables adjustments to ensure the required filling volume.

[0067] (4) A manufacturing planning support device described in any one of (1) to (3), comprising a manufacturing condition update unit that updates the manufacturing conditions by changing the number of passes or the welding conditions when the judgment unit determines that the target position of the other pass is included. According to this modeling planning support device, modeling conditions that make the actual layered shape closer to the target shape of the model can be automatically obtained.

[0068] (5) A manufacturing planning support device as described in (4), in which, based on the trajectory information of the updated manufacturing conditions and the information of the welding conditions, the shape prediction unit calculates the predicted shape, the judgment unit determines whether the target position of the other path is included, the trajectory information change unit changes the trajectory information, and the manufacturing conditions are updated by the manufacturing condition update unit, are repeatedly performed. According to this manufacturing planning support device, by repeatedly updating the manufacturing conditions, it is possible to automatically and widely search for the optimum number of passes, number of layers, and welding conditions.

[0069] (6) The modeling planning support device according to (4), wherein the modeling condition update unit adjusts an interval between target positions of adjacent passes in the plurality of passes in accordance with a target shape of the modeled object. According to this manufacturing planning support device, the layered shape of the weld bead changed by deleting the target position of the pass can be made closer to the target shape.

[0070] (7) The shaping planning support device according to (6), wherein the adjustment is performed by deleting the target positions of the other paths included inside the contour of the predicted shape and bringing the target positions of paths adjacent to the other paths closer to the contour of the predicted shape. According to this manufacturing planning support device, by bringing the target position of the path adjacent to the target position of the deleted path closer to the contour of the predicted shape, it is possible to avoid a situation in which the target position and the position of the bead surface become separated, resulting in the welding bead not being formed as expected, and it is possible to suppress missed swings of the manipulator and interference between the manipulator and other parts.

[0071] (8) The manufacturing planning support device according to (7), wherein the adjacent direction is a stacking direction of the weld beads or a lining direction of the weld beads. According to this manufacturing planning support device, a more appropriate weld bead layer shape can be obtained depending on the layering direction and arrangement direction of the weld beads.

[0072] (9) A modeling planning support method for determining modeling conditions for a model when manufacturing a model by repeatedly stacking weld beads formed by melting a filler material held by a manipulator using a heat source device, the method comprising: acquiring trajectory information including a target position of a path for forming the weld bead and information on welding conditions for forming the weld bead; A predicted shape of a plurality of the weld beads stacked on top of each other is obtained based on the trajectory information and the welding condition information. determining whether a target position of any pass other than a target position of a pass that forms the weld bead is included inside a contour of a predicted shape of any of the weld beads in a cross section perpendicular to a longitudinal direction of the weld bead; If the target position of the other path is included inside the contour, the target position of the other path is deleted from the trajectory information. A method for supporting design planning. According to this manufacturing planning support method, a predicted shape of the weld bead is calculated based on the acquired trajectory information and welding condition information, and if it is determined that the target positions of other passes are included inside the contour of the predicted shape, the target positions of the other passes are deleted from the trajectory information. As a result, even if the predicted shape of the layered weld bead does not match the target shape, the number of layers and passes can be automatically adjusted to obtain an appropriate layered shape.

[0073] (10) The method for supporting manufacturing planning according to (9), wherein, when it is determined that the target position of the other pass is included, the number of passes or the welding conditions are changed to update the manufacturing conditions. According to this modeling planning support method, modeling conditions that make the actual layered shape closer to the target shape of the model can be automatically obtained.

[0074] (11) A program for executing a modeling planning support procedure for determining modeling conditions for a model when manufacturing a model by repeatedly stacking weld beads formed by melting a filler material held by a manipulator using a heat source device, the program comprising: On the computer, a step of acquiring trajectory information including a target position of a path for forming the weld bead and information on welding conditions for forming the weld bead; a step of determining a predicted shape of a plurality of the weld beads stacked on top of each other based on the trajectory information and the welding condition information; determining whether a target position of any pass other than a target position of a pass that forms the weld bead is included inside a contour of a predicted shape of any of the weld beads in a cross section perpendicular to a longitudinal direction of the weld bead; a step of deleting the target position of the other path from the trajectory information when the target position of the other path is included inside the contour; A program for executing. This program calculates the predicted shape of the weld bead based on the acquired trajectory information and welding condition information, and if it determines that the target positions of other passes are included inside the contour of the predicted shape, it deletes the target positions of the other passes from the trajectory information.As a result, even if the predicted shape of the layered weld bead does not match the target shape, the number of layers and passes is automatically adjusted to obtain an appropriate layered shape.

[0075] (12) The program described in (11), further comprising the step of updating the forming conditions by changing the number of passes or the welding conditions when it is determined that the target position of the other pass is included. This program automatically obtains the molding conditions that make the actual layered shape closer to the target shape of the object. [Explanation of symbols]

[0076] 11 Modeling control section 13 Modeling Department 15. Modeling planning support device 17 Manipulator 19 Filler metal supply section 19a Reel 19b Feeding mechanism 21 Manipulator control unit 23 Heat source control unit 25 Torch 27 Base 27a Recess 31 Printing condition acquisition section 33 Shape Prediction Unit 35 Judgment section 37 Trajectory information change section 39 Printing condition update section 41 Bottom 43 Arc 45 Bottom 47a, 47b Hanging part 51 Target shape 53 Unwelded area 100 Additive manufacturing equipment B, B1, B2, B3, B4, B5, B1-1, B1-2, B1-3 Weld bead BM0 Rectangular bead model BM1, BM2, BM3, BMn models Dh, Dw Biting amount H bead height L1, L2, L3, L4 layers LD alignment direction M filler metal P position P1, P2, P3, PS, PS1, PS2, PS3 Pass SD stacking direction S0 target shape W sculpture

Claims

1. 1. A manufacturing planning support device that determines manufacturing conditions for a model of an object when manufacturing a model by repeatedly stacking weld beads formed by melting a welding wire held by a manipulator with an arc using a heat source device, the device comprising: a forming condition acquisition unit that acquires trajectory information including a target position of a path that forms the weld bead, and information on welding conditions that form the weld bead, including a welding current, a welding voltage, a moving speed of a torch of a manipulator, and a feed speed of the welding wire; a shape prediction unit that calculates a predicted shape of a plurality of the weld beads stacked on top of each other based on a bead model corresponding to the trajectory information and the welding condition information; a determination unit that determines whether a target position of any pass other than a target position of a pass that forms the weld bead is included inside a contour of a predicted shape of any of the weld beads in a cross section perpendicular to a longitudinal direction of the weld bead; a trajectory information change unit that deletes the target position of the other path from the trajectory information when the target position of the other path is included inside the contour; A modeling planning support device comprising:

2. the determination unit determines whether the target position of the other path is included in the contour according to an amount that the target position of the other path penetrates into the inside of the contour. The modeling planning support apparatus according to claim 1 .

3. The shape prediction unit predicts the predicted shape, and the determination unit determines whether the target position of the other path is included, for each path. The modeling planning support apparatus according to claim 2 .

4. a modeling condition update unit that updates the modeling conditions by changing the number of passes or the welding conditions when the determination unit determines that the target position of the other pass is included; The modeling planning support apparatus according to claim 1 .

5. Based on the trajectory information of the updated modeling conditions and information on the welding conditions, the shape prediction unit calculates the predicted shape, the determination unit determines whether the target position of the other path is included, the trajectory information change unit changes the trajectory information, and the modeling condition update unit updates the modeling conditions. The modeling planning support apparatus according to claim 4.

6. the modeling condition updating unit adjusts a distance between target positions of adjacent passes in the plurality of passes in accordance with a target shape of the modeling object. The modeling planning support apparatus according to claim 4.

7. the adjustment includes deleting a target position of the other path included inside the contour of the predicted shape and bringing a target position of a path adjacent to the other path closer to the contour of the predicted shape; The modeling planning support apparatus according to claim 6.

8. The adjacent direction is a stacking direction of the weld beads or an arrangement direction of the weld beads. The modeling planning support apparatus according to claim 7 .

Images