Method and system for optimizing stacking path reflecting industrial robot characteristics

Abstract

Provided are a method and a system for optimizing a stacking path. A method for optimizing a stacking path reflecting industrial robot characteristics according to an embodiment of the present invention includes: a step in which a system analyzes thermodynamic properties of a product by using a thermal analysis simulation model; and a step in which the system corrects and optimizes a tool path, including the movement path of a laser and the intensity of the laser in each region constituting the movement path, on the basis of the analysis result. Accordingly, thermal stress and deformation that occurs in an additive manufacturing process can be minimized.

Description

Method and system for optimizing stacking paths by reflecting industrial robot characteristics

[0001] The present invention relates to additive manufacturing technology, and more particularly, to a method and system for optimizing a layering path using thermodynamic property analysis and a toolpath-applied layering thermal analysis technique.

[0002] Existing additive manufacturing technologies have failed to effectively control thermal stress and deformation caused by real-time changing heat distribution, resulting in deterioration of part quality.

[0003] In particular, as the laser moves, heat concentration occurs in a specific area.

[0004] As a result, there is a problem that the mechanical properties of the product deteriorate due to residual stress and deformation caused by heat concentration.

[0005] Therefore, it is necessary to find a way to reduce thermal stress and deformation in the additive manufacturing process.

[0006] The present invention has been devised to solve the above problems, and the purpose of the present invention is to provide a method and system for optimizing a lamination path to minimize thermal stress and deformation occurring in a lamination manufacturing process and to improve the mechanical quality of a part.

[0007] In order to achieve the above object, according to one embodiment of the present invention, a method for optimizing a stacking path reflecting industrial robot characteristics includes: a step in which a system analyzes thermodynamic properties of a product using a thermal analysis simulation model; and a step in which the system corrects and optimizes a tool path including a laser movement path and the intensity of the laser in each area constituting the movement path based on the analysis result.

[0008] And the optimization step can correct the tool path so that the heat input of the product is controlled based on the analysis results of a thermal analysis simulation model that includes heat dissipation characteristics to prevent overheating in the additive manufacturing process of the product.

[0009] In addition, in the optimization step, if Q is the existing heat input, ΔE is the analysis result value of a thermal analysis simulation model including heat loss characteristics, and Emax is the total amount of energy that the material (element) of the additive manufacturing process can additionally contain, Qnew (controlled heat input) can be calculated by referring to the following formula.

[0010] (Formula) Qnew = Q×(1-ΔE / Emax)

[0011] And the optimization step is that, once Qnew is calculated, the toolpath can be corrected so that the intensity of the laser in each area that constitutes the movement path is adjusted according to the calculated Qnew.

[0012] In addition, the optimization step may select one or more optimization target areas based on the temperature distribution for the entire area extracted from the analysis results of the thermal analysis simulation model, and perform tool path optimization so that the heat input of the selected optimization target areas is controlled.

[0013] And, according to the present embodiment, the method for optimizing a layering path reflecting industrial robot characteristics may further include a step of the system applying an optimized tool path to a layering manufacturing process of a product, thereby optimizing the layering manufacturing process.

[0014] Additionally, the thermal analysis simulation model may be a simulation model that performs thermal analysis on an additive manufacturing process while adjusting variables such as laser power, scan speed, travel path, and interlayer spacing according to an initially generated toolpath or the most recently calibrated toolpath.

[0015] Meanwhile, according to another embodiment of the present invention, a system for optimizing a stacking path reflecting industrial robot characteristics includes an analysis module that analyzes thermodynamic properties of a product using a thermal analysis simulation model; and an optimization module that corrects and optimizes a tool path including a laser movement path and the intensity of the laser in each area constituting the movement path based on the analysis results.

[0016] As described above, according to embodiments of the present invention, by optimizing the lamination path in the lamination manufacturing process, thermal stress and deformation occurring in the lamination manufacturing process can be minimized, and the mechanical quality of the part can be improved.

[0017] Figure 1 is a drawing provided for the description of a method for optimizing a stacking path reflecting industrial robot characteristics according to one embodiment of the present invention.

[0018] Figures 2 and 3 are drawings illustrating analysis results of a thermal analysis simulation model according to one embodiment of the present invention.

[0019] Figure 4 is a drawing illustrating the entire area extracted from the analysis results of the thermal analysis simulation model illustrated in Figures 2 and 3, divided into multiple areas.

[0020] FIG. 5 is a drawing provided for explaining the process of selecting an optimization target area among the multiple divided areas illustrated in FIG. 4.

[0021] Figure 6 is a drawing illustrating the results of comparing the temperature changes before and after optimization for the optimization target area illustrated in Figure 5.

[0022] Figure 7 is a drawing illustrating a comparison result of temperature changes before and after optimization in the analysis results of a thermal analysis simulation model according to one embodiment of the present invention.

[0023] FIG. 8 is a drawing provided to explain the configuration of an industrial robot feature-reflecting layering path optimization system according to one embodiment of the present invention, and

[0024] FIG. 9 is a drawing provided for a more detailed configuration description of the processor illustrated in FIG. 8.

[0025] Hereinafter, the present invention will be described in more detail with reference to the drawings.

[0026] FIG. 1 is a drawing provided to explain a method for optimizing a stacking path reflecting industrial robot characteristics according to one embodiment of the present invention, and FIGS. 2 and 3 are drawings illustrating analysis results of a thermal analysis simulation model according to one embodiment of the present invention.

[0027] The method for optimizing a stacking path reflecting industrial robot characteristics according to the present embodiment (hereinafter collectively referred to as the “optimization method”) can minimize thermal stress and deformation occurring in an additive manufacturing process and improve the mechanical properties (quality) of a part by optimizing the stacking path.

[0028] Specifically, the optimization method can analyze the thermodynamic properties of a product using a thermal analysis simulation model (S110), and based on the analysis results, optimize the tool path, which includes the laser movement path and the laser intensity in each area constituting the movement path (S120). Then, when the optimization of the tool path is completed, the optimization method can optimize the additive manufacturing process by applying the optimized tool path to the additive manufacturing process of the product (S130).

[0029] Specifically, the optimization method can prevent overheating in the additive manufacturing process of a product by correcting the tool path so that the heat input of the product is controlled based on the analysis results of a thermal analysis simulation model including heat dissipation characteristics.

[0030] To this end, the optimization method corrects the existing heat input (Q, unit: W) extracted from the analysis results of the thermal analysis simulation model to a new heat input (Qnew, unit: W) by referring to the following formula, and when Qnew is calculated, the tool path can be corrected so that the intensity of the laser in each area constituting the movement path is adjusted according to the calculated Qnew.

[0031] (Formula) Qnew = Q×(1-ΔE / Emax)

[0032] Here, ΔE is the analysis result of a thermal analysis simulation model including heat dissipation characteristics (unit: J), and Emax represents the total amount of energy (unit: J) that the material (element) of the additive manufacturing process can additionally store. Here, Emax can be experimentally defined depending on the material of the process.

[0033] For example, assume that Q in the process is 220 W, and the heat dissipation characteristic ΔE is calculated to be 40 J, and Emax is experimentally defined as 250 W. In this case, the adjusted heat input Qnew is calculated as follows:

[0034] Qnew = 220×(1-(40 / 250))=220×(1-0.16) = 220×0.84 = 184.8W

[0035] In addition, the optimization method does not perform toolpath optimization for the entire area of ​​the product, but divides the entire area into multiple areas, selects optimization target areas requiring toolpath optimization, and performs toolpath optimization only for the selected optimization target areas, thereby saving time and resources consumed in the optimization process.

[0036] Specifically, the optimization method can select an optimization target area requiring toolpath optimization based on a temperature distribution for the entire area extracted from the analysis results of a thermal analysis simulation model among multiple areas in order to select an optimization target area.

[0037] Figure 4 is a drawing illustrating the entire area extracted from the analysis results of the thermal analysis simulation model illustrated in Figures 2 and 3, divided into multiple areas.

[0038] FIG. 4 is a drawing illustrating a temperature distribution for the entire area when the entire area is divided into Zone 1 to Zone 5, and in this case, the optimization method considers the temperature distribution for the first, fourth, and fifth areas to be within a normal range based on the temperature distribution for the entire area, so that the second zone (Zone 2) and the third zone (Zone 3) can be selected as optimization target areas requiring tool path optimization.

[0039] And when the optimization target areas (e.g. Zone 2 and Zone 3) are selected, a new heat input (Qnew) is calculated for each selected optimization target area by referring to the above formula, and toolpath optimization can be performed so that the heat input of each optimization target area is adjusted according to the calculated Qnew.

[0040] Additionally, this toolpath optimization process can iteratively correct the toolpath to minimize expected thermal stress and product distortion.

[0041] Here, FIG. 5 is a drawing provided for explaining a process of selecting an optimization target area from among the multiple divided areas illustrated in FIG. 4, FIG. 6 is a drawing illustrating a comparison result of temperature changes before and after optimization for the optimization target area illustrated in FIG. 5, and FIG. 7 is a drawing illustrating a comparison result of temperature changes before and after optimization in an analysis result of a thermal analysis simulation model according to one embodiment of the present invention.

[0042] In Fig. 6, the heat input of the second zone (Zone 2) is adjusted from 800W in the first optimization attempt to 600W in the third optimization attempt (a total of three repetitions), and the temperature distribution of the second zone is most stable in the third attempt. In addition, the heat input of the third zone (Zone 3) is adjusted from 850W in the first optimization attempt to 750W in the third optimization attempt (a total of three repetitions), and the temperature distribution of the third zone is most stable in the third attempt.

[0043] Meanwhile, the thermal analysis simulation model refers to a simulation model that performs thermal analysis on the additive manufacturing process while adjusting the variables of laser power, scan speed, movement path, and interlayer spacing according to the initially generated tool path or the most recently corrected tool path.

[0044] And the product produced by the additive manufacturing process is described as a hemispherical product as illustrated in FIGS. 2 to 4, but this is for convenience of explanation, and the shape of the product can be implemented in various shapes that allow the additive manufacturing process, and is not limited to a specific shape.

[0045] FIG. 8 is a drawing provided for explaining the configuration of an industrial robot feature-reflecting layering path optimization system (hereinafter collectively referred to as “system”) according to one embodiment of the present invention.

[0046] The system according to the present embodiment is provided to execute the optimization method described above with reference to FIGS. 1 to 7.

[0047] To this end, the system includes a communication unit (110), an input unit (120), a processor (130), an output unit (140), and a storage unit (150).

[0048] The communication unit (110) is a means for communicating with external devices including a 3D printer and connecting to a server, cloud, etc. via a network, and can transmit / receive / upload / download data required for 3D printing.

[0049] The input unit (120) is a means for receiving parameters, etc. required for the processor (130) to operate.

[0050] The processor (130) can analyze the thermodynamic properties of a product by utilizing a thermal analysis simulation model, and based on the analysis results, can correct and optimize a tool path including the movement path of the laser and the intensity of the laser in each area constituting the movement path.

[0051] And, when the optimization work of the tool path is completed, the processor (130) can apply the optimized tool path to the additive manufacturing process of the product so that the additive manufacturing process is optimized.

[0052] The output unit (140) is a display that outputs information generated / processed by the processor (130) to the screen, and the storage unit (150) is a storage medium that provides the storage space necessary for the processor (130) to operate normally.

[0053] FIG. 9 is a drawing provided for a more detailed configuration description of the processor (130) illustrated in FIG. 8.

[0054] Referring to FIG. 9, the processor (130) according to the present embodiment may include an analysis module (131), a toolpath optimization module (132), and a process optimization module (133).

[0055] The analysis module (131) can analyze the thermodynamic properties of a product by utilizing a thermal analysis simulation model.

[0056] The toolpath optimization module (132) can optimize the toolpath by correcting the toolpath including the movement path of the laser and the intensity of the laser in each area constituting the movement path based on the analysis results.

[0057] The process optimization module (133) can optimize the additive manufacturing process by applying the optimized tool path to the additive manufacturing process of the product when the optimization work of the tool path is completed.

[0058] Meanwhile, it goes without saying that the technical idea of ​​the present invention can also be applied to a computer-readable recording medium containing a computer program that performs the functions of the device and method according to the present embodiment. In addition, the technical idea according to various embodiments of the present invention can be implemented in the form of computer-readable code recorded on a computer-readable recording medium. The computer-readable recording medium can be any data storage device that can be read by a computer and store data. For example, the computer-readable recording medium can be a ROM, a RAM, a CD-ROM, a magnetic tape, a floppy disk, an optical disk, a hard disk drive, etc. In addition, the computer-readable code or program stored on the computer-readable recording medium can be transmitted through a network connected between computers.

[0059] In addition, although the preferred embodiments of the present invention have been illustrated and described above, the present invention is not limited to the specific embodiments described above, and various modifications can be made by a person having ordinary skill in the art to which the present invention pertains without departing from the gist of the present invention as claimed in the claims, and such modifications should not be understood individually from the technical idea or prospect of the present invention.

Claims

1. A step in which the system analyzes the thermodynamic properties of a product using a thermal analysis simulation model; and A method for optimizing a layering path reflecting industrial robot characteristics, comprising: a step of optimizing a tool path including a laser movement path and the intensity of the laser in each area constituting the movement path based on analysis results; 2. In claim 1, The optimization step is, A method for optimizing a lamination path reflecting industrial robot characteristics, characterized in that the tool path is corrected so that the heat input of the product is controlled based on the analysis results of a thermal analysis simulation model including heat dissipation characteristics to prevent overheating in the lamination manufacturing process of the product.

3. In claim 2, The optimization step is, A method for optimizing a stacking path reflecting industrial robot characteristics, characterized in that Qnew (adjusted heat input) is calculated by referring to the following formula, when Q is the existing heat input, ΔE is the analysis result value of a thermal analysis simulation model including heat loss characteristics, and Emax is the total amount of energy that a material (element) of an additive manufacturing process can additionally contain. (Formula) Qnew = Q×(1-ΔE / Emax) 4. In claim 3, The optimization step is, A method for optimizing a layering path reflecting industrial robot characteristics, characterized in that when Qnew is calculated, the tool path is corrected so that the intensity of the laser in each area constituting the movement path is adjusted according to the calculated Qnew.

5. In claim 2, The optimization step is, A method for optimizing a stacking path reflecting industrial robot characteristics, characterized in that one or more optimization target areas are selected based on a temperature distribution for the entire area extracted from the analysis results of a thermal analysis simulation model, and tool path optimization is performed so that the heat input of the selected optimization target areas is controlled.

6. In claim 1, A method for optimizing a layered path reflecting industrial robot characteristics, characterized in that the system further includes a step of optimizing an additive manufacturing process by applying an optimized tool path to the additive manufacturing process of a product.

7. In claim 1, The thermal analysis simulation model is, A method for optimizing a layer path reflecting industrial robot features, characterized in that the method is a simulation model that performs thermal analysis on an additive manufacturing process while adjusting variables of laser power, scan speed, movement path, and interlayer spacing according to an initially generated tool path or the most recently corrected tool path.

8. Analysis module that analyzes the thermodynamic properties of a product using a thermal analysis simulation model; and An industrial robot feature-reflecting layer path optimization system including a tool path optimization module that corrects and optimizes a tool path including a laser movement path and the intensity of the laser in each area constituting the movement path based on analysis results.

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