Three-dimensional manufacturing device and method for controlling three-dimensional manufacturing device

Abstract

A three-dimensional manufacturing device according to the present disclosure manufactures an article by discharging a fluid, the device comprising: a support portion that supports a pallet on which the article is to be placed in a manufacturing area; a dispenser unit that has an application head for discharging a liquid substance onto the article; an imaging portion that captures an image of the liquid substance discharged from the dispenser unit in a discharge area provided around the manufacturing area; and a control portion that detects the discharge state of the dispenser unit on the basis of the image captured by the imaging portion.

Description

Three-dimensional modeling device and method for controlling the three-dimensional modeling device

[0001] This specification discloses a three-dimensional printing apparatus and a method for controlling the three-dimensional printing apparatus.

[0002] Conventionally, a method for calibrating a fluid dispensing system has been proposed, for example, by using a fluid dispenser to dispense fluid to an external reference point, obtaining the position of the dispensed fluid using an optical sensor, calculating the distance between the position of the external reference point and the position of the dispensed fluid, determining a correction value based on the calculated distance, and using the correction value to improve the placement accuracy of the dispensed fluid (see, for example, Patent Document 1).

[0003] Special table 2017-512120 publication

[0004] However, although the device described in Patent Document 1 can improve the fluid placement accuracy by performing calibration of the fluid dispensing system, it is still not sufficient, and further improvement is desired.

[0005] The present disclosure has been made to solve such problems, and its main object is to provide a three-dimensional printing device and a control method for a three-dimensional printing device that can further improve the ejection accuracy of liquid material.

[0006] The present disclosure has adopted the following means to achieve the above-mentioned main object.

[0007] The three-dimensional printing device disclosed herein is a three-dimensional printing device that ejects a fluid to form a model, and includes: a support unit that supports a pallet on which the model is placed in a modeling area; a dispenser unit having an application head that ejects a liquid material onto the model; an imaging unit that images the liquid material ejected from the dispenser unit onto an ejection area disposed around the modeling area; and a control unit that detects the ejection state of the dispenser unit based on the image captured by the imaging unit.

[0008] In this three-dimensional modeling device, by detecting the liquid discharge state in a discharge area surrounding the modeling area, the detection process and the discharge process onto the model are performed in closer areas, thereby further improving the accuracy of liquid discharge.

[0009] 1 is a schematic explanatory diagram showing an example of a printing system 10. FIG. 1 is a schematic explanatory diagram showing an example of the structure of a three-dimensional modeling apparatus 11 as seen from the front. FIG. 2 is an explanatory diagram showing an example of the outlines of each discharge unit and a moving unit 25. FIG. 3 is an explanatory diagram showing an example of the outlines of a pallet 60. FIG. 4 is an explanatory diagram showing an example of the outlines of a dispenser unit 40. A flowchart showing an example of a molded object production processing routine. A flowchart showing an example of a detection processing routine. An explanatory diagram showing an example of a detection result image and detection information 24. An explanatory diagram showing an example of a schematic of a pallet 60B.

[0010] This embodiment will be described below with reference to the drawings. FIG. 1 is a schematic explanatory diagram showing an example of a printing system 10 according to the present disclosure. FIG. 2 is a schematic explanatory diagram showing an example of the structure of a three-dimensional modeling apparatus 11 as viewed from the front. FIG. 3 is an explanatory diagram showing an example of the outline of a first discharging unit 30, a second discharging unit 35, and a moving unit 25. FIG. 4 is an explanatory diagram showing an example of the outline of a pallet 60 including a discharging region 64. FIG. 5 is an explanatory diagram showing an example of the outline of a dispenser unit 40. In this embodiment, the left-right direction (X-axis), the front-rear direction (Y-axis), and the up-down direction (Z-axis) are as shown in FIGS. 1 to 5 .

[0011] The printing system 10 is configured as a production line in which a 3D modeling device 11 forms a modeled object as a first process, forms predetermined components on the modeled object as a second process, and then a mounting device 12 mounts components. The 3D modeling device 11 may form a wiring pattern of metal wiring as the second process, and the mounting device 12 may mount components P at predetermined positions on the wiring pattern. In addition to the mounting device 12, the printing system 10 may also include one or more mounting-related devices, such as a printing device that prints solder as a viscous fluid on the modeled object, a print inspection device that inspects the printing results, a mounting inspection device that inspects the mounting results, and a transport device that transports the modeled object. While the printing system 10 shown in FIG. 1 includes one mounting device 12, multiple mounting devices 12 may also be included.

[0012] The mounting device 12 is a device that mounts components on a model formed by the 3D modeling device 11. The mounting device 12 includes a control device, a transport processing unit 13, a component supply unit 14, an imaging unit 16, a mounting unit 17, an operation panel, and a communication unit. The control device is configured as a microprocessor centered around a mounting control unit such as a CPU, and controls the entire device. The control device outputs control signals to the transport processing unit 13, the component supply unit 14, the imaging unit 16, the mounting unit 17, and the operation panel, and inputs signals from the transport processing unit 13, the component supply unit 14, the imaging unit 16, the mounting unit 17, and the operation panel. The control device includes a storage unit, which is a large-capacity storage medium such as a flash memory. The storage unit stores mounting information including information on the components P to be mounted, the arrangement order and positions of the components to be mounted on the model, and the installation position of a feeder 15 that picks up the components. The transport processing unit 13 carries in, transports, fixes at the mounting position, and carries out the pallet 60 on which the shaped object is placed. The component supply unit 14 is a unit that supplies components P to the mounting unit 17. The component supply unit 14 mounts feeders 15 having reels holding components in one or more mounting units. The imaging unit 16 is a camera that captures images of the upward direction and captures images of the components P held by the mounting head 19 of the mounting unit 17. The operation panel is a unit that accepts input from the worker and presents information to the worker. This operation panel includes a display unit and an operation unit with a touch panel and buttons. The mounting unit 17 is a unit that collects components P from the component supply unit 14 and places them on the shaped object fixed to the transport processing unit 13. The mounting unit 17 includes a head moving unit 18, a mounting head 19, and a collection member. The head moving unit 18 includes a slider that moves in the X and Y directions along a guide rail, and a motor that drives the slider. The mounting head 19 is removably attached to the slider, picks up one or more components, and is moved in the X and Y directions by the head moving unit 18. One or more picking members are removably attached to the underside of the mounting head 19. The picking members may be suction nozzles that use negative pressure to pick up components, or may be mechanical chucks that mechanically hold components. The communication unit is an interface that exchanges information with the 3D printing device 11 and external devices such as a management device (not shown).

[0013] The 3D printing apparatus 11 is a 3D printing apparatus that models and manufactures a shaped object having a substrate, wiring, etc. The shaped object may include, for example, a substrate, wiring formed on and / or within the substrate, and components disposed on and / or within the substrate. The material to be modeled is not particularly limited, and examples thereof include resin and ceramics. As shown in FIGS. 1 and 2 , the 3D printing apparatus 11 includes a control device 20, a memory unit 22, a moving unit 25, a flattening unit 28, a first discharging unit 30, a first maintenance unit 33, a first curing unit 34, a second discharging unit 35, a second maintenance unit 38, a second curing unit 39, a pressing unit 70, a dispenser unit 40, an inspection unit 73, an operation panel 78, and a communication unit 79. The 3D printing apparatus 11 also includes, as structural components, a first gantry 1, a second gantry 2, a third gantry 3, and a housing 4. Here, the 3D modeling device 11 will be mainly described as a device that performs a process of forming an insulator, such as a substrate as a base material for a model, using the first discharging unit 30, and then forming a wiring pattern on the formed insulator using the second discharging unit 35. Note that the first discharging unit 30 and the second discharging unit 35 are collectively referred to simply as "discharging units," the first discharging head 32 and the second discharging head 37 are collectively referred to simply as "discharging heads," the first maintenance unit 33 and the second maintenance unit 38 are collectively referred to simply as "maintenance units," and the first curing unit 34 and the second curing unit 39 are collectively referred to simply as "curing units."

[0014] The control device 20 is configured as a microprocessor centered on a control unit 21 such as a CPU, and controls the entire 3D printing apparatus 11. The control device 20 exchanges information with a memory unit 22 and each unit. The memory unit 22 is, for example, a large-capacity storage medium such as a flash memory. The memory unit 22 stores modeling job information 23 and detection information 24. The modeling job information 23 includes information such as the shape and size of the object to be manufactured and the wiring pattern to be formed on the substrate. The detection information 24 includes detection results such as the ejection results of the fluid from the first discharging unit 30 and the second discharging unit 35, and the ejection results of the liquid material from the dispenser unit 40. The detection information 24 may include, for example, captured images of droplets ejected onto the ejection areas 64 and / or coordinate data of the ejection positions of the droplets ejected onto the ejection areas 64. The 3D printing apparatus 11 executes the modeling process based on the information stored in the memory unit 22. In addition, as will be described in more detail later, the control unit 21 also executes a process of detecting the ejection state of the dispenser unit 40 based on an image captured by the imaging unit 51 of the ejection area 64 into which the dispenser unit 40 has ejected the liquid material.

[0015] The moving unit 25 moves a pallet 60 as an object onto which the fluid is to be discharged. The moving unit 25 includes a support part 26 that supports and fixes the pallet 60, and a pallet moving part 27 that includes a drive part that moves the support part 26 in the front-to-rear direction and an elevating part that raises and lowers the support part 26 in the up-and-down direction.

[0016] The pallet 60 is a plate-like member having an area where a shaped object is formed. As shown in FIG. 4 , the pallet 60 has a shaping area 61, a reference area 62, a receiving area 63, and a discharging area 64. A removable film is attached to the top surface of the pallet 60, and by replacing this film, the next shaped object can be produced. The shaping area 61 is a printing area where a shaped object is formed by the first discharging unit 30, and a printing area where a predetermined pattern is formed on the shaped object by the second discharging unit 35. The reference area 62 is a reference mark that serves as a reference position for the pallet 60. A plurality of reference areas 62 are provided outside the shaping area 61. The pallet 60 has four reference areas 62. The shape of the reference area 62 is not particularly limited as long as it allows coordinates to be determined, and examples include a circle, a polygon such as a rectangle, and the like. The receiving area 63 is an area that receives unwanted fluid or liquid material discharged from the first discharge head 32, the second discharge head 37, and the application head 42. The discharge area 64 is an area that detects the discharge position of the liquid material discharged from the dispenser unit 40. The discharge area 64 is provided in an empty area that exists on the periphery of the shaping area 61. The discharge area 64 is an area that is different from the inspection area 74 described below, and is located closer to the shaping area 61 than the inspection area 74. The discharge area 64 is an area where the dispenser unit 40 can perform a discharge process on multiple locations in order to detect the discharge status of the dispenser unit 40 multiple times. The discharge area 64 may be provided with multiple areas where a single process of detecting the position of the discharged droplets can be performed. The number of discharge areas 64 that can be provided around the shaping area 61 may be equal to the number of areas required for a single shaping process on the shaping area 61. This three-dimensional modeling apparatus 11 is equipped with three dispensers 45, and, for example, 12 discharge detections can be performed for each dispenser 45, ensuring an area for 36 detections. After one modeling process, the pallet 60 is removed from the support part 26 and completely cleaned.

[0017] The first discharging unit 30 is a unit that discharges a fluid serving as a base material onto the pallet 60. The first discharging unit 30 is movably disposed to the left of the first gantry 1, which is fixed to a front region in the Y-axis direction of the housing 4 of the 3D modeling apparatus 11. The first discharging unit 30 includes a first moving unit 31, a first discharging head 32, and a first fluid processing unit. The first moving unit 31 includes a slider that moves along the X-axis direction while being guided by a guide rail, and a motor that drives the slider. The first discharging head 32 is attached to the slider, and the first discharging head 32 moves along the X-axis direction in accordance with the movement of the slider. The first moving unit 31 moves the first discharging head 32 between a standby position and a discharging position on the pallet 60. The first discharging head 32 is a modeling material discharging head that discharges the fluid onto the pallet 60 to form a model. The first discharging head 32 includes a first nozzle and a discharging drive unit. The first nozzle is formed in the nozzle plate. This first nozzle is an opening hole that discharges the fluid supplied from the first fluid processing unit onto the pallet 60. The discharge drive unit, for example, discharges the fluid toward the pallet 60, and may be, for example, a piezoelectric element. The fluid discharged by the first discharge head 32 may be, for example, a liquid curable resin (e.g., ultraviolet curable resin, thermosetting resin, two-component mixed curable resin, etc.), a thermoplastic resin, or a slurry in which a solvent is mixed with a solid such as an inorganic substance. The first fluid processing unit is a unit that delivers the fluid and includes a first supply tank that stores the fluid and a first recovery tank that stores the recovered fluid.

[0018] The first maintenance unit 33 is a unit that seals and protects the first ejection head 32, and performs ejection maintenance based on the ejection state of the first ejection head 32. The first maintenance unit 33 has, for example, a first cap that seals the first ejection head 32, a first ejection receiving portion that receives fluid ejected from the first ejection head 32, and a first cleaning portion that cleans the first ejection head 32. The ejection maintenance includes, for example, performing a flushing process and performing a process of wiping and cleaning the nozzle plate of the first ejection head 32.

[0019] The first curing unit 34 is a unit that performs a predetermined process on the fluid discharged from the first discharging head 32 onto the pallet 60 or onto a model that has been cured on the pallet 60, thereby curing the fluid. The first curing unit 34 may be a unit that irradiates the fluid discharged onto the modeling region 61 with light of a predetermined wavelength, such as ultraviolet light, to cure the fluid. The first curing unit 34 may also be a unit that dries or bakes the fluid depending on its material. For example, every time a layer of fluid is formed on the modeling region 61 by the first discharging head 32, the pallet 60 is moved below the first curing unit 34 to cure the fluid.

[0020] The second discharging unit 35 is a unit that discharges a fluid onto the pallet 60 or onto the shaped object, which will become wiring formed inside or on its surface. The second discharging unit 35 is movably disposed to the right of the first gantry 1, which is fixed to the front region of the housing 4 in the Y-axis direction. The second discharging unit 35 includes a second moving unit 36, a second discharging head 37, and a second fluid processing unit. The second moving unit 36 ​​includes a slider that moves along the X-axis direction while guided by a guide rail, and a motor that drives the slider. The second discharging head 37 is attached to the slider, and the second discharging head 37 moves along the X-axis direction in accordance with the movement of the slider. The second moving unit 36 ​​moves the second discharging head 37 between a standby position and a discharging position on the pallet 60. The second discharging head 37 is a wiring material discharging head that discharges fluid onto the shaped object on the pallet 60 to form wiring. Like the first discharging head 32, the second discharging head 37 includes a second nozzle and a discharging drive unit. The second ejection head 37 has the same structure and function as the first ejection head 32, and detailed description thereof will be omitted. Examples of fluids ejected from the second nozzles include a mixed liquid in which a solid is mixed with a solvent, or a solution in which a resin is dissolved in a solvent. Examples of such fluids include a conductive paste in which metal particles are dispersed in a resin that hardens when heated. For example, in a conductive paste, when the resin hardens and shrinks, the dispersed metal particles come into contact with each other. This allows the conductive paste to exhibit conductivity. The resin in the conductive paste is, for example, an organic adhesive, and exhibits adhesive strength upon hardening. Examples of fluids that form wiring patterns include a mixed liquid in which metal powder as a conductive material is dispersed in an organic solvent, and a metal ink conductive fluid.

[0021] The second maintenance unit 38 is a unit that seals and protects the second ejection head 37, and also performs ejection maintenance based on the ejection state of the second ejection head 37. The second maintenance unit 38 has, for example, a second cap that seals the second ejection head 37, a second ejection receiving portion that receives fluid ejected from the second ejection head 37, and a second cleaning portion that cleans the second ejection head 37. The ejection maintenance includes the flushing process and cleaning process described above.

[0022] The second curing unit 39 is a unit that performs a predetermined process on the fluid ejected from the second discharging head 37 onto the building region 61 of the pallet 60 or onto a hardened model on the pallet 60, thereby hardening the fluid. The second curing unit 39 may be configured to harden the fluid ejected onto the building region 61 by irradiating it with light of a predetermined wavelength, such as infrared light. The second curing unit 39 may also be configured to dry or bake the fluid depending on its material. For example, every time a layer of fluid is formed on the pallet 60 by the second discharging head 37, the pallet 60 is moved underneath the second curing unit 39, and the second curing unit 39 hardens the fluid.

[0023] The flattening unit 28 flattens the surface of the fluid dispensed onto the pallet 60 and / or the model using a flattening member. The flattening member may be, for example, a flattening roller that rotates relative to the model, or a flat flattening blade.

[0024] The dispenser unit 40 is a unit that applies a liquid material to a model on a pallet 60. As shown in FIGS. 1, 2, and 5, the dispenser unit 40 is movably disposed on a second gantry 2 fixed to a central region in the Y-axis direction of a housing 4 of the 3D modeling apparatus 11. The dispenser unit 40 is disposed on a transport path that transports the pallet 60 to and from the mounting apparatus 12. In addition to the coating process using the dispenser, the dispenser unit 40 is configured to perform a coating amount detection process, a pallet 60 loading / unloading process, an imaging process, a height measurement process, and the like. The dispenser unit 40 includes a coating movement unit 41, a coating head 42, a pressure adjustment unit 43, a dispenser 45, and a discharge amount detection unit 54. The dispenser unit 40 also includes a working unit 50 disposed on the coating head 42. The working unit 50 includes an imaging unit 51, a height detection unit 52, and a mounting / transport unit 53.

[0025] The moving applicator unit 41 includes a slider that moves along the X-axis direction while being guided by a guide rail disposed on the second gantry 2, and a motor that drives the slider. A coating head 42 is attached to the slider, and the coating head 42 moves along the X-axis direction as the slider moves. As shown in FIG. 1 , the moving applicator unit 41 moves the coating head 42 between a working position above a pallet 60 in the central region along the X-axis of the housing 4, a carry-in / out position on the mounting device 12 side, and a standby position on the opposite side from the mounting device 12. The coating head 42 is a structure that is moved along the X-axis direction by the moving applicator unit 41. One or more dispensers 45 and a working unit 50 are disposed in the coating head 42. The coating head 42 is provided with dispensers 45A to 45C, which apply conductive paste, filler, and the like. The dispensers 45A to 45C are collectively referred to as "dispensers 45." The dispenser 45 has a discharge port 47 for discharging the liquid material and includes a syringe 46 containing the liquid material. As shown in FIG. 5 , the syringe 46 is a columnar member containing the liquid material, and discharges the liquid material from the discharge port 47 provided at the tip of the syringe 46 by pressure applied from above. Examples of the liquid material include resins with different viscosities and conductivities, such as resins with dispersed conductive materials and insulating resins. The pressure adjustment unit 43 is connected to the dispenser 45 and includes a pressurizer, a pressure reducer, a switching valve, and an adjustment valve. The pressurizer applies positive pressure to the syringe 46 to discharge the liquid material, and the pressure reducer applies negative pressure to the syringe 46 to prevent leakage from the discharge port 47. In the application head 42, an elevator (not shown) lowers the syringe 46 to a discharge position, and after discharging the liquid material, the elevator raises the syringe 46 to a standby position.

[0026] The imaging unit 51 is a camera that captures images below. The imaging unit 51 captures, for example, the reference portion 62 of the pallet 60, the object on the printing region 61, the discharge region 64 arranged around the printing region 61, and the inspection region 74 of the inspection unit 73. The imaging unit 51 captures images of droplets discharged from the dispenser unit 40 or the discharge unit to the discharge region 64, and droplets discharged from the discharge unit to the inspection region 74. The height detection unit 52 is configured as a sensor that moves a contact terminal at its tip downward and determines the height of the object it contacts based on the position of contact with the object. The height detection unit 52 is used to measure the height of the pallet 60 and the object on the pallet 60. The mounting transport unit 53 is used to transport the pallet 60 to the mounting device 12 and transport the pallet 60 from the mounting device 12. The mounting and transporting unit 53 has a rod structure that can extend downward, and moves the pallet 60 by contacting its tip with the edge of the pallet 60 and pushing it out or hooking and pulling it in. The discharge amount detection unit 54 detects the amount of liquid material dispensed from the dispenser 45. The discharge amount detection unit 54 is disposed in the central region of the housing 4 and below the standby position of the application head 42. The discharge amount detection unit 54 includes a receiving member and a measuring unit. The receiving member is a removable, dish-shaped member that contains the liquid material. The measuring unit is a device that measures weight. The discharge amount detection unit 54 applies an arbitrary pressure to the syringe 46 and measures the amount of liquid material dispensed from the syringe 46 per unit time. Using this measurement value, the control device 20 controls the discharge amount of the liquid material to an appropriate value.

[0027] The pressing unit 70 is a unit that presses the object on the pallet 60, or a liquid material applied to the pallet 60 or the object. The pressing unit 70 is disposed on the third gantry 3 that is fixed to the rear region in the Y-axis direction of the housing 4 of the 3D printing device 11. The pressing unit 70 may be configured to heat and press the object. The pressing unit 70 is configured to include a pressing section that presses the object with a pressing member 71, a heating section that heats the pressing section, and a pressing and transporting section 72 that transports the pallet 60 in and out. The pressing member 71 is a member that comes into contact with the object and applies pressure to it. When the pressing unit 70 includes a heating section, the pressing member 71 is a member that comes into contact with the object and applies pressure and heat to it. The pressing and conveying section 72 carries the pallet 60 in and out of the pressing unit 70 disposed at a position outside the moving lane of the moving unit 25. The pressing and conveying section 72 may be mechanically similar to the mounting and conveying section 53.

[0028] The inspection unit 73 is a unit that inspects the ejection state of the first ejection unit 30 and / or the second ejection unit 35. The inspection unit 73 is composed of a mark substrate as an inspection area 74 and an imaging unit 51. The inspection unit 73 inspects the ejection positions of the ejection units by causing fluid ejected from the first ejection unit 30 or the second ejection unit 35 to land on the surface of a film fixed on the mark substrate and capturing an image of this with the imaging unit 51. The inspection area 74 is disposed in front of the support unit 26, separate from the pallet 60.

[0029] The operation panel 78 is a unit that receives input from the operator and presents information to the operator. The operation panel 78 includes a display unit and an operation unit with a touch panel and buttons. The communication unit 79 is an interface that exchanges information with external devices such as the mounting device 12 and a management device (not shown).

[0030] Next, the 3D printing process of the 3D printing apparatus 11 configured as described above will be described. FIG. 6 is a flowchart showing an example of a molded object production process routine executed by the control unit 21 of the control device 20. This routine is stored in the storage unit 22 and is executed by the control device 20 after the operator inputs a command to execute the production process. When this routine starts, the control unit 21 of the control device 20 first reads and acquires the molding job information 23 from the storage unit 22 (S100) and executes a calibration process (S110). The calibration process is a process that, when the apparatus is started, checks the operation of each unit, such as the discharge unit, maintenance unit, curing unit, dispenser unit 40, pressing unit 70, and inspection unit 73, and performs corrections to ensure operational accuracy. Here, a detection process, which is part of the calibration process and is executed by the dispenser unit 40, to detect and correct the discharge position of the dispenser 45 will be described.

[0031] 7 is a flowchart showing an example of a detection processing routine executed by the control unit 21 of the control device 20. This routine is stored in the storage unit 22 and is executed at the time of detection execution, which includes at least one of when the 3D modeling apparatus 11 is started and before the dispenser unit 40 is used. Here, the control unit 21 executes this detection processing routine in the calibration processing of S110 and the dispenser processing of S210. When this routine starts, the control unit 21 of the control device 20 first sets the dispenser 45 for which the detection processing of the discharge position is to be executed (S300). Here, the control unit 21 sets the dispensers 45A, 45B, and 45C in this order. Next, the control unit 21 acquires the position of the discharge region 64 for which the detection processing is to be executed (S310). The control unit 21 sets the dispensers 45A, 45B, and 45C in order, starting with the number 1 assigned to the discharge region 64. Next, the control unit 21 moves the support unit 26 on which the pallet 60 is disposed to the working position of the application head 42, and also moves the application head 42 above the set discharge area 64 (S320), causing the liquid material to be discharged from the set dispenser 45 (S330). Here, the control unit 21 executes discard discharge, which discharges the liquid at a discard position in the discharge area 64, and then executes detection discharge, which performs detection. As shown in FIG. 4 , the control unit 21 executes multiple discharges of discard droplets Dt, and then executes discharge of detection droplets Dd. By discharging the discard droplets Dt, the control unit 21 can stabilize the discharge of droplets from the dispenser 45.

[0032] Next, the control unit 21 captures an image of the discharged region 64 into which the droplets have been discharged using the imaging unit 51, and performs a detection process for the detection droplets Dd from the captured image (S340). Next, the control unit 21 determines whether the discharge positions of the detection droplets Dd are within a predetermined tolerance range (S350). The tolerance range can be set so that the performance required for the model is met, such as ensuring that the liquid material formation position deviation is equal to or less than a predetermined value, for example, that the resistance value is equal to or less than a predetermined value if the liquid material is a conductive material, or that the filling rate is equal to or greater than a predetermined value if the liquid material is a filler material. If the discharge positions of the detection droplets Dd are not within the tolerance range, the control unit 21 determines whether discharge position correction has been performed a predetermined number of times (S360). The number of retries can be set to, for example, the number of times that the discharge position can be corrected by discharge position correction, such as two, three, or five times. If the discharge position correction has not been performed the predetermined number of times, the control unit 21 performs discharge position correction (S370). The control unit 21 executes ejection position correction so as to cancel out the amount of positional deviation between the ejection position and the target position. After S370, the control unit 21 executes the processes from S310 onward. That is, the control unit 21 acquires the position of the next ejection region 64, and executes the ejection position detection process and ejection position correction until the ejection position falls within the allowable range and until the predetermined number of retries is reached.

[0033] On the other hand, if the predetermined number of retries has been performed in S360, the control unit 21 determines that it is difficult to bring the ejection position within the allowable range by ejection position correction, and outputs a warning to that effect to the operation panel 78 (S380). Next, the control unit 21 determines whether or not the measures to address the ejection abnormality have been completed (S390). When the operator confirms the warning, the operator performs work such as cleaning the dispenser 45 or replacing the syringe 46. If the measures to address the ejection abnormality have not been completed, the control unit 21 continues to output the warning in S380.

[0034] On the other hand, after the countermeasure for the discharge abnormality is completed in S390, or when the discharge position is within the allowable range in S350, the control unit 21 determines whether or not the discharge position detection process has been completed for all the dispensers 45 (S400). When the discharge position detection process has not been completed for all the dispensers 45, the control unit 21 executes the process from S300 onwards. That is, the control unit 21 sets the next dispenser 45, acquires the position of the discharge region 64 where the discharge process is executed, and executes the discharge position detection process and discharge position correction until the discharge position is within the allowable range and until the predetermined number of retries is reached.

[0035] On the other hand, when the discharge position detection process for all dispensers 45 is completed in S400, the control unit 21 executes the discharge process of the fluid and liquid material from the discharge head of the discharge unit and the dispenser 45 of the application head 42 to one discharge area 64 (S410). Then, the control unit 21 images the discharge area 64 into which each droplet has been discharged, stores the discharge position detection results in the storage unit 22 (S420), and ends this routine. The discharge position detection results may be, for example, an image of the discharge area 64, or information on the discharge position of each droplet, such as the coordinates of each droplet on the discharge area 64, or both. Note that in the calibration process at the time of device startup, the processes of saving the detection results in S410 and S420 may be omitted.

[0036] 8A and 8B are explanatory diagrams of detection result images of fluids and liquids discharged from the discharge heads of the discharge units and the dispensers 45 of the coating head 42 to one discharge area 64. FIG. 8A is an explanatory diagram of a detection result image 80 of normal discharge, FIG. 8B is an explanatory diagram of a detection result image 80B when there is an error for each gantry, and FIG. 8C is an explanatory diagram of a detection result image 80C when there is an error on the support part 26 side. As shown in FIG. 8A , in the discharge process of S410, the control unit 21 controls the first discharge unit 30 and the dispenser unit 40 so that they are aligned in a line at a predetermined interval. The detection result image 80 includes the structure droplets Ds discharged from the first discharge head 32, the wiring droplets Dc discharged from the second discharge head 37, the first droplets D1 discharged from the dispenser 45A, the second droplets D2 discharged from the dispenser 45B, and the third droplets D3 discharged from the dispenser 45C. The discharge unit is disposed on the first gantry 1, and the dispenser unit 40 is disposed on a second gantry 2 different from the first gantry 1. Arranging these droplets involves movement of each head and movement of the pallet 60. Therefore, the detection result image 80 and the detection information 24 obtained by digitizing the detection result image 80 can distinguish, based on the positional relationship of the droplets, whether there is a problem on the head side that discharges the droplets ( FIG. 8B ), or whether there is a problem on the pallet 60 or support unit 26 side that receives the droplets ( FIG. 8C ). The three-dimensional modeling device 11 saves this detection result as a log of the discharge status.

[0037] Returning to the description of the 3D printing process in FIG. 6 , after the calibration process is performed in S110, the control unit 21 determines whether it is time to inspect the first discharging unit 30 and the second discharging unit 35 (S120). The inspection timing may be, for example, when new production starts, when a predetermined number of objects, such as five or ten, have been produced, or when a predetermined time, such as 30 minutes or one hour, has elapsed. If it is time to inspect, the control unit 21 performs an inspection process for the first discharging head 32 and / or the second discharging head 37 (S130). In this process, the control unit 21 performs the inspection process using the inspection unit 73. Specifically, the control unit 21 moves a mark substrate having an inspection area 74 below the first discharging head 32 or the second discharging head 37, ejects fluid onto the inspection area 74, captures an image of the inspection area 74 with the imaging unit 51, and determines the ejection state of the fluid.

[0038] After S130, or if S120 indicates that the inspection timing is not met, the control unit 21 determines whether the maintenance timing is met (S140). The maintenance timing may be, for example, when a defective nozzle is found during the inspection process, when a predetermined number of shaped objects, such as five or ten, have been produced, or when a predetermined time, such as 30 minutes or one hour, has elapsed. If the maintenance timing is met, the control unit 21 executes a maintenance process for the first ejection head 32 and / or the second ejection head 37 (S150). In this process, the control unit 21 executes a maintenance process for the first ejection unit 30 and the second ejection unit 35 using the first maintenance unit 33 and the second maintenance unit 38. Specifically, the control unit 21 moves the first ejection head 32 below the first ejection receiving portion or moves the second ejection head 37 below the second ejection receiving portion, and executes a flushing process to forcibly eject fluid. Alternatively, the control unit 21 moves the first cleaning unit below the first ejection head 32 and performs a cleaning process on the nozzle plate with the cleaning member. Alternatively, the control unit 21 moves the second cleaning unit below the second ejection head 37 and performs a cleaning process on the nozzle plate with the cleaning member.

[0039] After S150, or if it is not the timing for maintenance in S140, the control unit 21 determines whether it is time to perform the first printing by the first discharging unit 30 based on the modeling job information 23 (S160). If it is time to perform the first printing, the control unit 21 executes the first printing process (S170). In the first printing process, the control unit 21 causes the first discharging unit 30 to discharge fluid onto the pallet 60, executes a flattening process in the flattening unit 28, and hardens the discharged fluid in the first hardening unit 34. After S170, or if it is not the timing for performing the first printing in S160, the control unit 21 determines whether it is time to perform the second printing based on the modeling job information 23 (S180). If it is time to perform the second printing, the control unit 21 executes the second printing process (S190). In the second printing process, the control unit 21 causes the second discharging unit 35 to discharge fluid onto the pallet 60 and / or the model, and causes the second curing unit 39 to harden the discharged fluid.

[0040] After S190, or if it is not the timing to perform the second printing in S180, the control unit 21 determines whether it is the timing for the dispenser process based on the modeling job information 23 (S200). If it is the timing for the dispenser process, the control unit 21 executes the dispenser process using the dispenser unit 40 (S210). In this process, the control unit 21 first executes the above-described detection process routine, for example, detects the amount of liquid material discharged per unit time using the discharge amount detection unit 54, and, taking these results into account, executes a process of applying conductive paste from the dispenser 45 onto the modeled object or filling grooves or the like of the modeled object with resin from the dispenser 45. In the detection process routine for the dispenser process, the detection process for the discharge position may be executed only for the dispenser 45 to be used. In this case, once the detection process for the relevant dispenser 45 is completed in S400, the routine may be terminated without executing the detection process for the other dispensers 45. Furthermore, in the detection process routine for this dispenser process, the processes of S410 to S420 may be omitted as appropriate. After the liquid material is applied from the dispenser 45, the control unit 21 applies pressure and heat with the pressing unit 70 to harden the liquid material.

[0041] After S210, or when it is not the timing for dispenser processing in S200, the control unit 21 determines whether it is the timing for mounting processing based on the modeling job information 23 (S220). If it is the timing for mounting processing, the control unit 21 executes a process of carrying the pallet 60 out and in to the mounting device 12 (S230). In this process, the control unit 21 causes the mounting transport unit 53 disposed in the dispensing head 42 to carry the pallet 60 out to the mounting device 12, and a process of carrying the pallet 60 carrying the shaped object on which components are arranged from the mounting device 12 into the mounting device 12. When the control unit of the mounting device 12 carries the pallet 60 in, it causes the mounting unit 17 to carry out a process of placing components on the shaped object based on the mounting job information.

[0042] After S230, or when it is not time to execute the mounting process in S220, the control unit 21 determines whether the production process is complete (S240). If the production process is not complete, the control unit 21 executes the processes from S120 onward. On the other hand, if the production process is complete in S240, this routine ends.

[0043] Here, the correspondence between the components of this embodiment and the components of the present disclosure will be clarified. The 3D modeling device 11 of this embodiment corresponds to an example of the 3D modeling device of the present disclosure, the support unit 26 corresponds to an example of a support unit, the dispenser unit 40 corresponds to an example of a dispenser unit, the application head 42 corresponds to an example of a application head, the discharge area 64 corresponds to an example of a discharge area, the imaging unit 51 corresponds to an example of an imaging unit, the control unit 21 corresponds to an example of a control unit, and the pallet 60 corresponds to an example of a pallet. Furthermore, the first discharge unit 30 corresponds to an example of a first discharge unit, the first discharge head 32 corresponds to an example of a first discharge head, the first moving unit 31 corresponds to an example of a first moving unit, the second discharge unit 35 corresponds to an example of a second discharge unit, the second discharge head 37 corresponds to an example of a second discharge head, the second moving unit 36 ​​corresponds to an example of a second moving unit, and the inspection area 74 corresponds to an example of an inspection area. In this embodiment, the operation of the three-dimensional printing device 11 is described, and an example of a control method for the three-dimensional printing device of the present disclosure is also clarified.

[0044] The three-dimensional printing apparatus 11 of the present embodiment described above is an apparatus that forms a model by discharging a fluid, and includes: a support unit 26 that supports a pallet 60 on which a model is placed in a printing region 61; a dispenser unit 40 having a dispensing head 42 that discharges a liquid material onto the model; an imaging unit 51 that captures an image of the liquid material discharged from the dispenser unit 40 onto a discharge region 64 disposed around the printing region 61; and a control unit 21 that detects a discharge state of the dispenser unit 40 based on the image captured by the imaging unit 51. In the three-dimensional printing apparatus 11, by detecting the discharge state of the liquid material in the discharge region 64 located around the printing region 61, the detection process and the discharge process onto the model are performed in closer regions, thereby further improving the discharge accuracy of the liquid material.

[0045] The pallet 60 also has discharge regions 64 where the dispenser unit 40 can perform discharge processing at multiple locations to detect the discharge state multiple times. In the three-dimensional modeling device 11, the ability to detect the discharge state multiple times can further improve the discharge accuracy of the liquid material. Furthermore, the control unit 21 controls the application head 42 to perform a discharge processing to detect the discharge state after performing multiple discarding processes of the liquid material in the discharge regions 64. In the three-dimensional modeling device 11, the multiple discarding processes can further stabilize the discharge state and improve the discharge accuracy of the liquid material. Furthermore, the control unit 21 corrects the discharge position of the liquid material using the reference portion 62 provided on the pallet 60 as a reference for the discharge regions 64. If the discharge position corrected in the discharge region 64 is not within a predetermined tolerance range, the control unit 21 retries the discharge state detection in the next discharge region 64. In the three-dimensional modeling device 11, the ability to retry the discharge state detection multiple times can further improve the discharge accuracy of the liquid material.

[0046] Furthermore, the control unit 21 controls the dispensing head 42 to execute a process for detecting the dispensing state of the dispenser unit 40 during detection execution, which includes at least one of when the device is started and before the dispenser unit 40 is used. This three-dimensional modeling device 11 can further improve the dispensing accuracy of the liquid material during device startup and before dispensing. Particularly during device startup, production stoppages due to misalignment of the dispensing position caused by a relatively long pause can be prevented. Furthermore, immediately before application, higher dispensing position accuracy can be ensured in response to changes in viscosity, etc., over the course of production time. Furthermore, the three-dimensional printing apparatus 11 includes a first discharging unit 30 having a first discharging head 32 that discharges a fluid that forms a pattern on a printing area 61, and a second discharging unit 35 having a second discharging head 37 that discharges a fluid that forms wiring on the pattern. The control unit 21 controls the dispenser unit 40 to discharge the liquid material, the first discharging head 32 to discharge the fluid, and the second discharging head 37 to discharge the fluid on the printing area 64, and stores the detection results obtained by capturing images of the liquid material and fluid droplets discharged on the printing area 64 using the imaging unit 51 in the storage unit 22. The three-dimensional printing apparatus 11 can use the stored captured images to perform quality checks after production, etc. Note that the detection results may include one or more of information regarding the discharge position, size, and shape of the liquid material and fluid, and the captured images.

[0047] Furthermore, the first discharging unit 30 and the second discharging unit 35 detect the discharging state of the fluid in an inspection region 74 that is different from the discharging region 64. In this three-dimensional modeling device 11, the discharging state of the first discharging unit 30 and the second discharging unit 35 can be further improved in the inspection region 74, and the accuracy of discharging the liquid material from the dispenser unit 40 in the discharging region 64 can be further increased. Furthermore, the three-dimensional modeling device 11 includes a pallet moving unit 27 that moves the support unit 26, the dispenser unit 40 includes a coating moving unit 41 that moves the dispensing head 42 onto the pallet 60, the first discharging unit 30 includes a first moving unit 31 that moves the first discharging head 32 onto the pallet 60, and the second discharging unit 35 includes a second moving unit 36 ​​that moves the second discharging head 37 onto the pallet 60. In this three-dimensional modeling device 11, the discharging accuracy can be further improved in response to changes in the discharging state and the like that occur in each of the components that move relative to one another.

[0048] It goes without saying that the three-dimensional modeling device 11 and the printing system 10 of the present disclosure are not limited to the above-described embodiment, and can be embodied in various forms as long as they fall within the technical scope of the present disclosure.

[0049] For example, in the above-described embodiment, the pallet 60 is provided with a discharge area 64 divided into multiple regions. However, this is not particularly limited, and an undivided discharge area 64B may be provided. FIG. 9 is an explanatory diagram showing an example of a schematic of a pallet 60B provided with a discharge area 64B. The discharge area 64B is an area in which the discharge position detection process can be performed multiple times. The control unit 21 may treat the discharge area 64B as a plurality of pseudo-regions. This pallet 60B can also further improve the discharge accuracy of the liquid material.

[0050] In the embodiment described above, the control unit 21 executes the process of discharging the liquid material into the discharge area 64, but this is not particularly limited, and the discarding process may be omitted. In this three-dimensional printing device 11, the detection process and the discharge process onto the model are performed in closer areas, so the discharge accuracy of the liquid material can be further improved.

[0051] In the above-described embodiment, the control unit 21 retries the process of detecting the ejection state in the next ejection area 64 when the ejection position resulting from the ejection position correction is not within the allowable range, but this is not particularly limited to this, and the retry may be omitted.

[0052] In the above-described embodiment, the control unit 21 executes the detection process for the liquid ejection state when the device is started and before the dispenser unit 40 is used, but this is not limited to this, and in addition to this, or instead, the control unit 21 may execute the detection process for the liquid ejection state under other conditions.

[0053] In the above-described embodiment, the detection process for the ejection state of the ejection unit is performed in the inspection area 74, but this is not limited to this, and the detection process for the ejection state of the ejection unit may also be performed on the ejection area 64.

[0054] In the above-described embodiment, the present disclosure has been described as the printing system 10, but is not particularly limited thereto, and may be the three-dimensional modeling device 11 alone, or may be the dispenser unit 40. Furthermore, in the above-described embodiment, the printing system 10 and the three-dimensional modeling device 11 are described, but the present disclosure may be a control method for the three-dimensional modeling device 11 or a program therefor.

[0055] The present disclosure may be configured as follows: For example, a control method for a three-dimensional printing device according to the present disclosure is a control method for a three-dimensional printing device that includes a support unit that supports a pallet on which a model is placed in a modeling region, and a dispenser unit having an application head that dispenses a liquid material onto the model, and that forms a model by discharging a fluid, the control method including the steps of: (a) capturing an image of a liquid material dispensed into a dispensing region that is disposed around the modeling region and receives the liquid material dispensed from the dispenser unit; and (b) detecting a dispensing state of the dispenser unit based on the image captured in step (a).

[0056] In this control method for a 3D printing device, similar to the above-described 3D printing device, the detection process and the dispensing process onto the model are performed in closer areas, thereby further improving the accuracy of dispensing the liquid material. Note that this control method for a 3D printing device may employ various aspects of the above-described 3D printing device, or may include additional steps that realize each function of the above-described 3D printing device.

[0057] This specification also discloses the technical idea of ​​changing "the three-dimensional printing device according to claim 1 or 2" to "the three-dimensional printing device according to any one of claims 1 to 3" in claim 4 as originally filed, the technical idea of ​​changing "the three-dimensional printing device according to claim 1 or 2" to "the three-dimensional printing device according to any one of claims 1 to 4" in claim 5 as originally filed, the technical idea of ​​changing "the three-dimensional printing device according to claim 1 or 2" to "the three-dimensional printing device according to any one of claims 1 to 5" in claim 6 as originally filed, and the technical idea of ​​changing "the three-dimensional printing device according to claim 6" to "the three-dimensional printing device according to claim 6 or 7" in claim 8 as originally filed.

[0058] The present disclosure is applicable to the technical field of devices that eject fluids and manufacture shaped objects.

[0059] REFERENCE SIGNS LIST 10 Printing system, 11 Three-dimensional modeling device, 12 Mounting device, 13 Transport processing unit, 14 Component supply unit, 15 Feeder, 16 Imaging unit, 17 Mounting unit, 18 Head moving unit, 19 Mounting head, 20 Control device, 21 Control unit, 22 Memory unit, 23 Modeling job information, 24 Detection information, 25 Moving unit, 26 Support unit, 27 Pallet moving unit, 28 Flattening unit, 30 First discharge unit, 32 First discharge head, 33 First maintenance unit, 34 First curing unit, 35 Second discharge unit, 37 Second discharge head, 38 Second maintenance unit, 39 Second curing unit, 40 Dispenser unit, 41 Application moving unit 41, 42 Application head, 43 Pressure adjustment unit, 45 Dispenser, 46 Syringe, 47 Discharge port, 50 Working unit, 51 Imaging unit, 52 Height detection unit, 53 Mounting and transport unit, 54 Discharge amount detection unit, 60 Pallet, 61 Building area, 62 Reference unit, 63 Receiving area, 64 Discharge area, 70 Pressing unit, 71 Pressing member, 72 Pressing and transport unit, 73 Inspection unit, 74 Inspection area, 78 Operation panel, 79 Communication unit, 80, 80B, 80C Detection result image D1 First droplet, D2 Second droplet, D3 Third droplet, Dc Wiring droplet, Dd Detection droplet, Ds Structure droplet, Dt Disposal droplet.

Claims

1. A three-dimensional shaping apparatus that ejects a fluid to shape a shaped object, comprising: a support portion that supports a pallet on which the shaped object is placed in a shaping region; a dispenser unit having an application head that ejects a liquid material onto the shaped object; an imaging unit that images the liquid material ejected from the dispenser unit in a discharge region disposed around the shaping region; and a control unit that detects a discharge state of the dispenser unit based on an image captured by the imaging unit.

2. The three-dimensional shaping apparatus according to claim 1, wherein the pallet is provided with the discharge region in which a discharge process can be executed at a plurality of locations by the dispenser unit for detecting the discharge state a plurality of times.

3. The three-dimensional shaping apparatus according to claim 1 or 2, wherein the control unit controls the application head to execute a discharge process in which the discharge state is detected after performing a plurality of discard processes of the liquid material in the discharge region.

4. The three-dimensional shaping apparatus according to claim 1 or 2, wherein the control unit performs discharge position correction of the liquid material using a reference portion provided on the pallet as a reference for the discharge region, and when the discharge position due to the discharge position correction in the discharge region is not within a predetermined allowable range, causes the detection of the discharge state to be retried in the next discharge region.

5. The three-dimensional shaping apparatus according to claim 1 or 2, wherein the control unit controls the application head to execute a process of detecting the discharge state of the dispenser unit at the time of detecting execution including at least one of when the apparatus is started up and before the dispenser unit is used.

6. The three-dimensional shaping apparatus according to claim 1 or 2, further comprising: a first discharge unit having a first discharge head that ejects a fluid constituting the shaped object onto the shaping region; and a second discharge unit having a second discharge head that ejects a fluid constituting a wiring onto the shaped object, wherein the control unit causes the discharge of the liquid material from the dispenser unit, the discharge of the fluid from the first discharge head, and the discharge of the fluid from the second discharge head to be executed in the discharge region, and stores, in a storage unit, a detection result obtained by imaging the liquid material and the fluid discharged onto the discharge region by the imaging unit.

7. The three-dimensional shaping apparatus according to claim 6, wherein the first discharge unit and the second discharge unit detect a discharge state of the fluid in an inspection area different from the discharge area.

8. The three-dimensional shaping apparatus according to claim 6, further comprising: a pallet moving unit that moves the support unit; wherein the dispenser unit has an application moving unit 41 that moves the application head onto the pallet; the first discharge unit has a first moving unit that moves the first discharge head onto the pallet; and the second discharge unit has a second moving unit that moves the second discharge head onto the pallet.

9. A control method for a three-dimensional shaping apparatus, comprising: a support unit that supports a pallet on which a shaped object is placed in a shaping area; and a dispenser unit having an application head that discharges a liquid material onto the shaped object, the method including: (a) imaging a liquid material discharged into a discharge area disposed around the shaping area and receiving the liquid material discharged from the dispenser unit; and (b) detecting a discharge state of the dispenser unit based on the image captured in step (a).

Images