JP2019150857A - Adjustment method for workpiece posture, and method of and device for producing molded material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To produce a high-quality model by laminating a welded bead on a work and a work posture adjusting method capable of adjusting the posture of a work having a circular cross section with high accuracy while suppressing equipment cost. To provide a manufacturing method and manufacturing equipment for a modeled object. SOLUTION: This is a work posture adjusting method for adjusting the posture of a work 20, and is a circumferential position R1, R2 which is a plurality of circumferential positions in axial positions Z1 and Z2 which are a plurality of axial positions of the work 20. In R3, the position detection process of contacting the filler metal M protruding from the torch 17 with the peripheral surface of the work 20 to detect the position, the coordinate calculation process of calculating the coordinates of the detected position, and the calculated position coordinates. It includes an inclination calculation process for calculating the inclination of the work 20 and a posture adjustment process for adjusting the posture of the work 20 to a preset posture by the support mechanism 16 based on the calculated inclination of the work 20. [Selection diagram] Fig. 1

Description

  The present invention relates to a workpiece posture adjusting method, a method for manufacturing a modeled object, and a manufacturing apparatus.

  In recent years, the need for 3D printers as production means has increased, and research and development have been conducted for practical application in the aircraft industry and the like, particularly for application to metal materials. A 3D printer using a metal material uses a heat source such as a laser or an arc to melt a metal powder or a metal wire, and laminates the molten metal to form a model.

  For example, as a technique for adjusting the posture of a workpiece when modeling a model, a probe-type touch sensor attached to a tool head and a reference triaxial displacement detection sensor provided in advance in a machine tool are used. There is one that detects a posture and adjusts the posture of a workpiece by a posture adjusting tool controlled by a controller based on the detection result (see Patent Document 1).

Japanese Patent Laid-Open No. 10-138075

By the way, when a workpiece made of columnar bar steel with a circular cross-sectional view is erected, and a modeled object is formed by forming a weld bead on the peripheral surface of the workpiece, an error occurs in the lamination position of the weld bead due to the tilt of the workpiece Quality may be reduced. This stacking position error increases as the workpiece becomes larger.
According to the posture adjustment technique described in Patent Document 1, it is possible to adjust the posture of the workpiece, but since a displacement detection sensor in the reference three-axis direction is required in addition to the touch sensor, the equipment cost increases. .

  An object of the present invention is to manufacture a high-quality molded article by laminating a welding bead on a workpiece and a workpiece posture adjusting method capable of adjusting the posture of a circular cross-sectional workpiece with high accuracy while suppressing facility costs. It is in providing the manufacturing method and manufacturing apparatus of a molded article which can do.

The present invention has the following configuration.
(1) A tool is moved along the circumferential surface of a columnar workpiece having a circular shape in cross-section supported by a support mechanism, and a welding bead is formed by melting and solidifying a filler material on the circumferential surface of the workpiece. A work posture adjustment method for adjusting the posture of the workpiece when modeling an object,
A position detection process for detecting the position by contacting the tool with the circumferential surface of the workpiece at a circumferential position that is a plurality of circumferential positions in an axial position that is a plurality of positions in the axial direction of the workpiece;
A coordinate calculation process for calculating the coordinates of the detected position;
An inclination calculation process for calculating the inclination of the workpiece from the coordinates of the calculated position;
A posture adjustment process for adjusting the posture of the workpiece to a preset posture by the support mechanism based on the calculated inclination of the workpiece;
Work posture adjustment method including
(2) A method of manufacturing a modeled object in which a modeled object is manufactured by forming a weld bead around the workpiece whose attitude is adjusted by the workpiece attitude adjusting method of (1) above.
(3) a support mechanism for supporting a columnar workpiece having a circular cross-sectional view;
A tool for forming a weld bead obtained by melting and solidifying a filler material;
A moving mechanism for moving the tool;
A controller that controls the moving mechanism, moves the tool along the peripheral surface of the workpiece, forms a weld bead that melts and solidifies the filler material on the peripheral surface of the workpiece, and forms a modeled object;
With
The controller is
By controlling the moving mechanism, the tool is brought into contact with the circumferential surface of the workpiece at a circumferential position that is a plurality of circumferential positions in an axial position that is a plurality of axial positions of the workpiece, and the position is detected. And
Calculate the coordinates of the detected position,
Calculate the tilt of the workpiece from the coordinates of the calculated position,
An apparatus for manufacturing a modeled article, which controls the support mechanism based on the calculated inclination of the workpiece and adjusts the posture of the workpiece to a preset posture.

  ADVANTAGE OF THE INVENTION According to this invention, the attitude | position of a cross-sectional circular shape workpiece | work can be adjusted with high precision, suppressing installation cost, and a high quality molded article can be manufactured by laminating | stacking a welding bead on a workpiece | work.

It is a typical schematic block diagram of the manufacturing system which forms a welding bead in a workpiece | work and manufactures a molded article. It is a side view of the workpiece | work supported by the support mechanism. It is a schematic perspective view of the molded article which laminated the welding bead on the work. It is a schematic side view of the workpiece | work supported by the support mechanism explaining the workpiece | work attitude | position adjustment method. It is a schematic side view of the workpiece | work supported by the support mechanism explaining the workpiece | work attitude | position adjustment method. It is a schematic side view of the workpiece | work supported by the support mechanism explaining the workpiece | work attitude | position adjustment method. It is a schematic perspective view of the workpiece | work explaining a position detection process. It is a schematic side view of the workpiece | work explaining a position detection process.

Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings.
FIG. 1 is a schematic schematic configuration diagram of a manufacturing system for manufacturing a modeled object by forming a weld bead on a workpiece.
The manufacturing system 100 having this configuration includes an additive manufacturing apparatus 11, a support mechanism 16, and a controller 15 that performs overall control of the additive manufacturing apparatus 11 and the support mechanism 16.

  The additive manufacturing apparatus 11 includes a welding robot (moving mechanism) 19 having a torch (tool) 17 on the tip shaft, and a filler material supply unit 23 that supplies a filler material (welding wire) M to the torch 17. The torch 17 holds the filler material M in a state protruding from the tip.

  The controller 15 includes a CAD / CAM unit 31, a trajectory calculation unit 33, a storage unit 35, and a control unit 37 to which these are connected.

  The welding robot 19 is an articulated robot, and the filler material M is supported on the torch 17 provided on the tip shaft so as to be continuously supplied. The position and orientation of the torch 17 can be arbitrarily set three-dimensionally within the range of the degree of freedom of the robot arm.

  The torch 17 has a shield nozzle (not shown), and shield gas is supplied from the shield nozzle. The arc welding method used in this configuration may be any of consumable electrode methods such as covered arc welding and carbon dioxide arc welding, and non-consumable electrode methods such as TIG welding and plasma arc welding. It is selected as appropriate.

  For example, in the case of the consumable electrode type, a contact tip is disposed inside the shield nozzle, and a filler material M to which a molten current is fed is held by the contact tip. The torch 17 generates an arc from the tip of the filler material M in a shield gas atmosphere while holding the filler material M. The filler material M is fed from the filler material supply unit 23 to the torch 17 by a feed mechanism (not shown) attached to a robot arm or the like. Then, when the melt material M that is continuously fed is melted and solidified while moving the torch 17, a linear weld bead 25 that is a melt-solidified body of the melt material M is formed on the workpiece 20.

  The heat source for melting the filler material M is not limited to the arc described above. For example, a heat source using other methods such as a heating method using both an arc and a laser, a heating method using plasma, and a heating method using an electron beam or a laser may be adopted. When heating by an electron beam or a laser, the amount of heating can be controlled more finely, the state of the weld bead can be maintained more appropriately, and the quality of the laminated structure can be further improved.

  The CAD / CAM unit 31 generates shape data of the model W to be produced, and then generates layer shape data representing the shape of each layer by dividing the data into a plurality of layers. The trajectory calculation unit 33 obtains the movement trajectory of the torch 17 based on the generated layer shape data. The storage unit 35 stores data such as the generated layer shape data and the movement trajectory of the torch 17.

  The control unit 37 drives the welding robot 19 by executing a drive program based on the layer shape data stored in the storage unit 35 and the movement trajectory of the torch 17. That is, the welding robot 19 moves the torch 17 while melting the filler metal M with an arc based on the movement trajectory of the torch 17 generated by the trajectory calculation unit 33 according to a command from the controller 15. In addition, in FIG. 1, a mode that the welding bead 25 is helically formed in the surrounding surface of the columnar workpiece | work 20 of the cross-sectional view circular shape standingly set (supported) by the perpendicular direction, and the modeling thing W is modeled is shown. Yes.

  As shown in FIG. 2, the support mechanism 16 has a positioning mechanism portion 41 and a base 43. The positioning mechanism portion 41 supports the base 43. The workpiece 20 is erected on the base 43. The workpiece 20 is disposed on the base 43 so that the central axis 20a is along the vertical direction. The support mechanism 16 is connected to the controller 15, and the controller 15 controls the positioning mechanism unit 41. In the support mechanism 16, the positioning mechanism portion 41 is driven by an instruction from the controller 15, and the inclination of the upper surface 43 a of the base 43 is adjusted.

  The manufacturing system 100 having the above configuration melts the melt material M while moving the torch 17 by driving the welding robot 19 along the movement trajectory of the torch 17 generated from the set layer shape data. The filler material M is supplied to the peripheral surface of the workpiece 20. Thereby, for example, as shown in FIG. 3, a modeled object W in which a plurality of welding beads 25 are spirally formed and stacked on the peripheral surface of the workpiece 20 is modeled.

  By the way, when the workpiece 20 made of columnar steel bar having a circular cross-sectional view is erected and the weld bead 25 is formed on the peripheral surface of the workpiece 20 to form the model W, the weld bead 25 is tilted by the inclination of the workpiece 20. There is a possibility that an error occurs in the stacking position and the quality is deteriorated. This stacking position error increases as the workpiece 20 becomes larger.

  For this reason, in this embodiment, before the welding bead 25 is formed on the peripheral surface of the workpiece 20, the workpiece posture adjustment for adjusting the posture of the workpiece 20 is performed. Work posture adjustment includes position detection processing, coordinate calculation processing, inclination calculation processing, and posture adjustment processing.

Next, a work posture adjustment method according to the present embodiment will be described.
(Position detection processing)
As shown in FIG. 4A, position detection is performed at a plurality of detection positions (locations indicated by arrows and circles in FIG. 4A) P on the peripheral surface of the workpiece 20. In this position detection, the controller 15 drives the welding robot 19 of the additive manufacturing apparatus 11 to bring the torch 17 close to the peripheral surface of the workpiece 20 as shown in FIG. This is performed by abutting the tip of the head with a detection position P on the peripheral surface of the workpiece 20. The controller 15 detects the tip position of the filler metal M brought into contact with the detection position P of the workpiece 20 from the position information of the welding robot 19.

  The position detection that is detected by contacting the filler material M of the torch 17 is performed at circumferential positions that are a plurality of circumferential positions in the axial position that is a plurality of positions in the axial direction of the workpiece 20. In this example, it is performed at three locations in the circumferential direction at two locations in the axial direction of the workpiece 20.

  As shown in FIGS. 5A and 5B, the axial positions are the axial positions Z1 and Z2 at the formation start position and the formation end position of the welding bead 25 on the workpiece 20. In this embodiment, the welding bead 25 is formed in a spiral shape from the lower side to the upper side with respect to the peripheral surface of the workpiece 20. Accordingly, the axial position of the detection position P is the axial position Z1 at the lower formation start position and the axial position Z2 at the upper formation end position. In determining the axial positions Z1 and Z2, in the controller 15, the control unit 37 is based on a modeling modeling diagram that is a modeling model of a preset modeling object W stored in the storage unit 35. The coordinate in the axial direction of the workpiece 20 at the formation start position and the formation end position is obtained, and the coordinates of the formation start position and the formation end position are set as axial positions Z1 and Z2.

  The circumferential position is a plurality of locations in the circumferential direction of the workpiece 20. For example, at the axial positions Z1, Z2 of the workpiece 20, three circumferential positions R1, R2, R3 are equally spaced in the circumferential direction.

  When the filler material M of the torch 17 is brought into contact with the detection position P of the workpiece 20 obtained as described above, the control unit 37 of the controller 15 performs modeling of the previously formed object W stored in the storage unit 35. Based on the modeling modeling diagram, the welding robot 19 is driven to move the torch 17 so that the filler metal M comes into perpendicular contact with the detection position P on the peripheral surface of the workpiece 20.

(Coordinate calculation process)
The controller 15 calculates the coordinates of the detection position P detected by the position detection process. Specifically, three coordinates of circumferential positions R1, R2, and R3 at the axial positions Z1 and Z2 of the workpiece 20 are calculated.

(Slope calculation processing)
Next, the controller 15 calculates the inclination of the workpiece 20 from the calculated coordinates of the contact position. Specifically, as shown in FIG. 4B, the inclination of the central axis 20a of the workpiece 20 with respect to the vertical line X is calculated.

(Attitude adjustment processing)
Subsequently, the controller 15 adjusts the posture of the workpiece 20 to a preset posture based on the calculated inclination of the workpiece 20. In this embodiment, it is set as the attitude | position which makes the workpiece | work 20 stand upright. Specifically, as shown in FIG. 4C, the controller 15 adjusts the inclination of the upper surface 43 a of the base 43 by driving the positioning mechanism portion 41 of the support mechanism 16. As a result, the posture of the workpiece 20 is adjusted so that the center axis 20a of the workpiece 20 coincides with the vertical line X.

  After adjusting the posture of the workpiece 20 by the above posture adjustment method, the controller 15 melts the filler material M while moving the torch 17 along the movement trajectory of the torch 17 generated from the set layer shape data. The melted filler material M is supplied to the peripheral surface of the workpiece 20. As a result, a plurality of weld beads 25 are spirally formed and stacked on the peripheral surface of the workpiece 20 to form a model W.

  As described above, according to the workpiece posture adjusting method according to the present embodiment, the workpiece is moved by moving the torch 17 along the circumferential surface of the columnar workpiece 20 having a circular shape in section when it is erected on the support mechanism 16. When the welding bead 25 in which the filler material M is melted and solidified is formed on the circumferential surface of the workpiece 20 to form the model W, the workpiece 20 can be erected in a state of being positioned with high accuracy. Thereby, even if the workpiece 20 is large, the weld bead 25 can be formed on the circumferential surface of the workpiece 20 while suppressing errors as much as possible, and a high-quality model W can be modeled. Further, since the position is detected by bringing the filler material M protruding from the torch 17 that forms the welding bead 25 into contact with the workpiece 20, it is not necessary to provide a separate sensor for position detection, and the equipment cost can be reduced. .

  Further, in the position detection process, the formation start position coordinates and the formation end positions, which are the position coordinates in the axial direction of the workpiece 20 at the formation start position and the formation end position of the weld bead 25, based on the modeling diagram of the modeled object W set in advance. The coordinates are obtained, and the axial positions Z1 and Z2 at which the filler metal M of the torch 17 is brought into contact with the workpiece 20 are determined from these formation start position coordinates and formation end position coordinates. Thereby, the range from the formation start position of the welding bead 25 to the formation end position can be positioned with high accuracy.

  Moreover, in the position detection process, the torch 17 is arranged such that the filler material M of the torch 17 is brought into perpendicular contact with the detection position P on the peripheral surface of the workpiece 20 based on a preset modeling diagram of the model W. Move. Thereby, the detection accuracy of the position of the workpiece | work 20 can be raised.

  And according to the manufacturing system 100 which is the manufacturing method and manufacturing apparatus of the modeling object which forms the welding bead 25 with respect to the workpiece | work 20 which adjusted the attitude | position with the workpiece | work attitude | position adjustment method, the workpiece 20 is large sized. Even so, the weld bead 25 can be formed on the peripheral surface of the workpiece 20 while suppressing the error as much as possible, and a high-quality model W can be modeled. Further, when positioning the workpiece 20, the position detection is performed by bringing the filler metal M protruding from the torch 17 which is a tool for forming the welding bead 25 into contact with the workpiece 20, so that a sensor for position detection is provided separately. There is no need, and equipment costs can be reduced.

It should be noted that the present invention is not limited to the above-described embodiments, and those skilled in the art can change or apply the configurations of the embodiments to each other or based on the description of the specification and well-known techniques. Is also within the scope of the present invention, which is intended to be protected.
For example, the support mechanism described above is not limited to a structure that supports the workpiece in the vertical direction, and may be a mechanism that supports the workpiece in another direction such as a horizontal direction.

As described above, the following items are disclosed in this specification.
(1) A tool is moved along the circumferential surface of a columnar workpiece having a circular shape in cross-section supported by a support mechanism, and a welding bead is formed by melting and solidifying a filler material on the circumferential surface of the workpiece. A work posture adjustment method for adjusting the posture of the workpiece when modeling an object,
A position detection process for detecting the position by contacting the tool with the circumferential surface of the workpiece at a circumferential position that is a plurality of circumferential positions in an axial position that is a plurality of positions in the axial direction of the workpiece;
A coordinate calculation process for calculating the coordinates of the detected position;
An inclination calculation process for calculating the inclination of the workpiece from the coordinates of the calculated position;
A posture adjustment process for adjusting the posture of the workpiece to a preset posture by the support mechanism based on the calculated inclination of the workpiece;
Work posture adjustment method including
According to this work posture adjustment method, it is possible to support a columnar work having a circular cross-sectional view in a highly accurately positioned state. Thereby, even if the workpiece is large, it is possible to form a high-quality molded article by forming a weld bead on the peripheral surface of the workpiece while suppressing errors as much as possible. In addition, since the position detection is performed by bringing a tool for forming a welding bead into contact with the workpiece, it is not necessary to provide a separate sensor for position detection, and the equipment cost can be reduced.

(2) In the position detection process, on the basis of a modeling figure set in advance, a formation start position coordinate and a formation end composed of the welding start position and the formation end position of the welding bead in the axial position of the workpiece. The work posture adjustment method according to (1), wherein position coordinates are obtained, and the axial position where the tool is brought into contact with the work is determined from the formation start position coordinates and the formation end position coordinates.
According to this work posture adjustment method, the axial position where the tool is brought into contact with the work is determined from the formation start position coordinates and the formation end position coordinates, which are the work position axial position coordinates of the weld bead formation start position and formation end position. Thereby, the range from the formation start position of the weld bead to the formation end position can be positioned with high accuracy.

(3) In the position detection process, based on a preset modeling drawing of the modeled object, the tool is moved so that the tool is brought into contact with the peripheral surface of the workpiece to be brought into contact with the tool vertically. (1) The work posture adjustment method according to (2).
According to this work posture adjustment method, the accuracy of detecting the position of the work can be increased by bringing the tool into contact with the peripheral surface of the work vertically.

(4) A method of manufacturing a modeled object in which a modeled object is manufactured by forming a weld bead around the workpiece whose attitude is adjusted by the workpiece attitude adjusting method according to any one of (1) to (3).
According to this method of manufacturing a modeled object, a high-quality modeled object can be manufactured by forming a weld bead on the peripheral surface of a workpiece positioned with high accuracy.

(5) a support mechanism for supporting a columnar workpiece having a circular shape in section,
A tool for forming a weld bead obtained by melting and solidifying a filler material;
A moving mechanism for moving the tool;
A controller that controls the moving mechanism, moves the tool along the peripheral surface of the workpiece, forms a weld bead that melts and solidifies the filler material on the peripheral surface of the workpiece, and forms a modeled object;
With
The controller is
By controlling the moving mechanism, the tool is brought into contact with the circumferential surface of the workpiece at a circumferential position that is a plurality of circumferential positions in an axial position that is a plurality of axial positions of the workpiece, and the position is detected. And
Calculate the coordinates of the detected position,
Calculate the tilt of the workpiece from the coordinates of the calculated position,
An apparatus for manufacturing a modeled article, which controls the support mechanism based on the calculated inclination of the workpiece and adjusts the posture of the workpiece to a preset posture.
According to this manufacturing apparatus of a modeled object, when a welded bead is formed on the peripheral surface of a columnar workpiece having a circular cross-sectional view, the controller supports the workpiece in a state of being positioned with high accuracy. Thereby, even if the workpiece is large, it is possible to form a high-quality molded article by forming a weld bead on the peripheral surface of the workpiece while suppressing errors as much as possible. Further, when the workpiece is positioned, the position detection is performed by bringing the tool for forming the welding bead into contact with the workpiece, so that it is not necessary to provide a separate sensor for position detection, and the equipment cost can be reduced.

15 Controller 16 Support mechanism 17 Torch (tool)
19 Welding robot (movement mechanism)
20 work 25 welding bead 100 manufacturing system (manufacturing equipment)
M filler metal R1, R2, R3 circumferential position W shaped object Z1, Z2 axial position

Claims (5)

A tool is moved along the peripheral surface of the columnar workpiece having a circular shape in cross-section supported by the support mechanism to form a weld bead in which the filler material is melted and solidified on the peripheral surface of the workpiece to form a model. A workpiece posture adjustment method for adjusting the posture of the workpiece when performing
A position detection process for detecting the position by contacting the tool with the circumferential surface of the workpiece at a circumferential position that is a plurality of circumferential positions in an axial position that is a plurality of positions in the axial direction of the workpiece;
A coordinate calculation process for calculating the coordinates of the detected position;
An inclination calculation process for calculating the inclination of the workpiece from the coordinates of the calculated position;
A posture adjustment process for adjusting the posture of the workpiece to a preset posture by the support mechanism based on the calculated inclination of the workpiece;
Work posture adjustment method including   In the position detection process, on the basis of a modeling diagram of the modeled object set in advance, a formation start position coordinate and a formation end position coordinate, which are the position coordinates in the axial direction of the workpiece at the formation start position and the formation end position of the welding bead, The work posture adjustment method according to claim 1, wherein the work position adjustment method is used to determine the axial position where the tool is brought into contact with the work from the formation start position coordinates and the formation end position coordinates.   2. In the position detection process, the tool is moved based on a preset modeling drawing of a modeled object so that the tool is brought into contact with the peripheral surface of the workpiece to be brought into contact with the tool perpendicularly. Alternatively, the work posture adjustment method according to claim 2.   The manufacturing method of the molded article which forms a welding bead around the said workpiece | work which adjusted the attitude | position with the workpiece | work attitude | position adjustment method as described in any one of Claims 1-3, and manufactures a molded article. A support mechanism for supporting a columnar workpiece having a circular shape in section,
A tool for forming a weld bead obtained by melting and solidifying a filler material;
A moving mechanism for moving the tool;
A controller that controls the moving mechanism, moves the tool along the peripheral surface of the workpiece, forms a weld bead that melts and solidifies the filler material on the peripheral surface of the workpiece, and forms a modeled object;
With
The controller is
By controlling the moving mechanism, the tool is brought into contact with the circumferential surface of the workpiece at a circumferential position that is a plurality of circumferential positions in an axial position that is a plurality of axial positions of the workpiece, and the position is detected. And
Calculate the coordinates of the detected position,
Calculate the tilt of the workpiece from the coordinates of the calculated position,
An apparatus for manufacturing a modeled article, which controls the support mechanism based on the calculated inclination of the workpiece and adjusts the posture of the workpiece to a preset posture.

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