This application is based on and claims priority under 35 USC 119 from Japanese Patent Application No. 2017-042835 filed Mar. 7, 2017.
The present invention relates to a fabrication management system, and a fabrication management control apparatus.
According to an aspect of the invention, there is provided a fabrication management system including a fabrication control apparatus and a fabrication management server. The fabrication control apparatus includes a composite fabrication unit that fabricates a fabricated component over a previously fabricated component to fabricate a finished fabricated object, and a controller that controls fabrication performed by the composite fabrication unit. The fabrication management server includes an instructing section that, by use of fabrication information about each of multiple fabricated components to be assembled into the finished fabricated object and positional information identifying a position onto which each fabricated component is assembled upon completion of the finished fabricated object, instructs fabrication to be performed by using the composite fabrication unit in accordance with fabrication procedure information used to sequentially perform fabrication in the height direction.
Exemplary embodiment of the present invention will be described in detail based on the following figures, wherein:
A communication network 10 is connected with the fabrication-order-receipt management control apparatus 14. The communication network 10 is, for example, a local area network (LAN) or an Internet network. The communication network 10 may include multiple LANs connected by a wide area network (WAN). Not all the communication networks including the communication network 10 need to be wired networks. That is, some or all of the communication networks may be wireless communication networks that transmit and receive information by radio.
The fabrication-order-receipt management control apparatus 14 has a body 16, and a user interface (UI) 18. The UI 18 includes a monitor 20 serving as a display, and a keyboard 22 and a mouse 24 each serving as an input operation unit.
The body 16 is connected with a media reader 26 that functions as an input source for ordering information required for placing a fabrication order.
The media reader 26 is provided with a slot that allows insertion of a recording medium 30 such as an SD memory. Ordering information recorded on the inserted recording medium is read and sent to the body 16.
Ordering information may be received from a PC 28 used for placing an order (to be sometimes also referred to as “ordering PC 28” hereinafter), which is connected to the communication network 10 and owned by the orderer. Although
The communication network 10 is connected with a control apparatus 34 that serves as a fabrication control apparatus owned by each of fabricated object manufacturers 32 that fabricate three-dimensional fabricated objects.
The control apparatus 34 manages multiple three-dimensional fabricators 36 (see
The fabricated object manufacturers 32 include multiple three-dimensional fabricators 36 (see
As illustrated in
The I/O 16D is connected with a network I/F 12 that enables communication with the communication network 10, the UI 18 (the monitor 20, the keyboard 22, and the mouse 24), and the media reader 26.
The I/O 16D is also connected with a hard disk 29 serving as a large-scale recording medium. The hard disk 29 temporarily stores order-receipt management information related to a received fabrication order.
The ROM 16C stores a program for executing a fabrication-order-receipt management control. Upon activation of the fabrication-order-receipt management control apparatus 14, the program is read from the ROM 16C and executed by the CPU 16A. The fabrication-order-receipt management control program may be recorded on, other than the ROM 16C, the hard disk 29 or other recording media.
In the exemplary embodiment, the fabricated object manufacturers have multiple kinds of three-dimensional fabricators 36 that employ different fabrication methods.
Examples of fabrication methods include binder jetting, directed energy deposition, material extrusion, material jetting, powder bed fusion, sheet lamination, and vat photopolymerization.
As illustrated in
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The seven three-dimensional fabricators 36A to 36G employing different fabrication methods described in (1) to (7) above are selectively owned by fabricated object manufacturers. Although
When the fabrication-order-receipt management control apparatus 14 receives a fabrication request for a three-dimensional fabricated object from an orderer, the fabrication-order-receipt management control apparatus 14 selects a fabrication method.
The fabrication-order-receipt management control apparatus 14 stores, on the hard disk 29 (see
The fabrication-order-receipt management control apparatus 14 determines which fabricated object manufacturer 32 owns the three-dimensional fabricator 36 that employs the selected fabrication method, and places a fabrication order with the control apparatus 34 managed by the corresponding fabricated object manufacturer 32.
When the control apparatus 34 of the fabricated object manufacturer 32 receives a fabrication request (including fabrication data, fabrication method, and the material used) for a three-dimensional fabricated object, the fabricated object manufacturer 32 fabricates the three-dimensional fabricated object by use of the three-dimensional fabricator 36. In some instances, the conditions used by the fabrication-order-receipt management control apparatus 14 to select a fabricated object manufacturer include delivery time and cost.
In some instances, the content of a received order (order sheet information) represents a request for fabrication of three-dimensional fabricated objects made from multiple different materials and assembled with each other into a finished object (composite fabricated object). In other words, the individual three-dimensional fabricated objects constituting the finished fabricated object and fabricated from multiple different materials are to be regarded as components of the finished fabricated object.
Three-dimensional fabricated objects (components) made from different materials are generally fabricated as follows. Basically, the three-dimensional fabricators 36 that employ different fabrication methods are selected to fabricate such components individually through separate processes, and then the fabricated components are assembled together at the orderer into a finished fabricated object.
In this case, assembly accuracy needs to be taken into account. Accordingly, such a fabrication process often requires a fabrication accuracy higher than that required for fabrication of a three-dimensional fabricated object made from a single material.
For example, as illustrated in
As illustrated in
Multiple three-dimensional fabricators 36 employing different fabrication methods are arranged in the direction of movement of the belt conveyor 38, and attached to a head holder 44. As a result, as the belt conveyor 38 moves, an already-fabricated component may be transported between the three-dimensional fabricators 36 employing different fabrication methods. This enables additional fabrication to be performed based on the already-fabricated component.
In this case, the three-dimensional fabricators 36 employing different fabrication methods that are to be attached to the head holder 44 are changed at the time of order receipt in accordance with each fabrication method required. This enhances general versatility in comparison to when a fixed set of three-dimensional fabricators 36 employing different fabrication methods is attached to the head holder 44.
The composite fabrication unit 40 employs a basic fabrication procedure described below. That is, while the belt conveyor 38 is sequentially moved in a one-way direction as indicated by the arrow A in
Some composite fabrication processes involve, rather than simply layering different three-dimensional fabricated objects on top of each other sequentially, fabricating three-dimensional fabricated objects while selecting different three-dimensional fabricators 36 in a complex manner.
For example,
In contrast,
Accordingly, with the exemplary embodiment, an operation process (fabrication workflows) is developed by also taking into account how components are assembled with each other, and when the orderer passes an order for composite fabrication to a fabricated object manufacturer, the orderer attaches the fabrication workflows to the placed order.
Although the fabrication-order-receipt management control apparatus 14 has the function of receiving a fabrication request including not only composite fabrication but also fabrication using a single material, and placing such a fabrication order with the fabricated object manufacturer 32, the following description of the function of the fabrication-order-receipt management control apparatus 14 will focus on the case of composite fabrication.
As illustrated in
The receiving unit 74 is connected to a fabrication information extracting unit 76. The fabrication information extracting unit 76 extracts fabrication information from information about a fabrication request received by the receiving unit 74. Fabrication information includes fabrication format data, specified material, delivery time, and cost.
Desirably, the fabrication format data is voxel data saved in a fabricatable voxel (FAV) format.
Overview of FAV Format
The FAV format retains not only the outer structure of 3D model data but also information on a range of attributes such as those defining the internal structure, materials to be used, colors, and connection strength. The FAV format enables designers to design both the exterior and interior of 3D model data as desired, thoroughly down to the finest details in a precise and intricate manner, and then save this data.
The FAV format is constructed based on voxel data.
Voxels are the three-dimensional equivalents of pixel values. Similar to the way pixels as two-dimensional pixel values are arranged in a two-dimensional configuration to create an image, a three-dimensional fabricated object is structured by arranging voxels as three-dimensional pixel values in a three-dimensional configuration.
That is, the FAV format represents 3D model data satisfying the following conditions.
Condition 1: The information required for fabrication (e.g., shape, material, color, or connection strength) is clearly defined for each three-dimensional location, for both the exterior and interior of 3D model data.
Condition 2: The 3D model data allows the user to design (CAD), analyze (CAE), and inspect (CAT) the 3D model data seamlessly in an integrated and two-way manner without having to convert data.
As illustrated in
The fabricating-material-type identifying unit 78 identifies the type of material to be used in fabrication. Fabrication requests according to the exemplary embodiment include a fabrication request for a three-dimensional fabricated object made from a single type of material, and a fabrication request (composite fabrication) for a fabricated object completed by assembling multiple three-dimensional fabricated objects made from multiple types of materials. The fabricating-material-type identifying unit 78 identifies a single or multiple types of materials, and sends the identified single or multiple types of materials to the fabrication method selecting unit 80.
The fabrication method selecting unit 80 is connected with a material/fabrication-method compatibility table memory 82, and a support-necessity determining unit 84.
The fabrication method selecting unit 80 checks the material type identified by the fabricating-material-type identifying unit 78 against the material/fabrication-method compatibility table read from the material/fabrication-method compatibility table memory 82, and selects a fabrication method that is compatible with the identified material type (see the three-dimensional fabricators 36A to 36G in
Further, based on fabrication format data received from the fabrication information extracting unit 76, for example, the fabrication method selecting unit 80 simulates mimicry of a three-dimensional fabricated object that will become a finished fabricated object, irrespective of whether the three-dimensional fabricated object is fabricated from a single material or a combination of multiple materials, and inquires the support-necessity determining unit 84 whether a support is required.
For example, suppose that an object is to be fabricated using two different kinds of materials. In this case, if the object to be fabricated includes a portion (overhang) such that the lower face of a component serving as an upper layer hangs over the upper face of a component serving as a lower layer underneath the upper layer, it is desired to fabricate a support to support the overhang. Accordingly, the support-necessity determining unit 84 illustrated in
In some instances, fabrication of a support requires the three-dimensional fabricator 36 to have, in addition to a fabrication head used for fabricating the target object to be fabricated, an auxiliary head used for fabricating the support.
As illustrated in
Accordingly, in selecting a fabrication method based on whether an object is to be fabricated from a single material or multiple materials, the fabrication method selecting unit 80 selects a fabrication method (and the fabricated object manufacturer 32 to which a fabrication request is to be made) by taking into account, in addition to the material/fabrication-method compatibility table, information about delivery time and cost received from the fabrication information extracting unit 76, as well as information about the current operating condition of the three-dimensional fabricator 36 received from the operating information reading unit 86. The fabrication method selecting unit 80 then sends information indicative of the selected fabrication method to a fabrication workflow developing unit 90 and an order sheet creating unit 91, which each serve as a generator. Desirably, the fabricated object manufacturer 32 is selected by taking factors such as fabrication method, delivery time, and price into account in addition to operating information.
The fabrication workflow developing unit 90 develops, in particular, a procedure to be followed by the composite fabrication unit 40 in fabricating a finished fabricated object through assembly of fabricated objects (components) made from multiple materials.
At time time, the composite fabrication unit 40 performs fabrication through either a basic or irregular procedure. In the basic procedure, while sequentially moving the belt conveyor 38 in a one-way direction as indicated by the arrow A in
Accordingly, the fabrication workflow developing unit 90 develops workflows N (N represents the number of steps) made up of multiple steps, including information such as the direction in which the belt conveyor 38 is moved in
The order sheet creating unit 91 creates an order sheet based on the fabrication method (and the fabricated object manufacturer 32) selected by the fabrication method selecting unit 80 and the workflows N developed by the fabrication workflow developing unit 90.
The order sheet creating unit 91, which is connected to a fabrication instructing unit 92 that functions as an instructing section, sends the created order sheet to the fabrication instructing unit 92.
As the fabrication instructing unit 92 instructs the fabricator management unit 88 to perform fabrication, the fabricator management unit 88 sends information related to the order sheet to the control apparatus 34 of the fabricated object manufacturer 32 that has been selected.
The operation of the exemplary embodiment will be described below with reference to the flowchart of
At step 100, it is determined whether a received fabrication instruction is an instruction to fabricate a composite object. If the determination is negative, the process transfers to step 102 where a normal fabrication process is executed, and this routine is ended.
A normal fabrication process refers to a fabrication process that uses a single material and a single three-dimensional fabricator 36 to fabricate a three-dimensional fabricated object. A detailed description of this fabrication process is herein omitted.
If the determination at step 100 is affirmative, the process transfers to step 104 where fabrication information is extracted from the received fabrication request. Fabrication information includes at least the following items of information: fabrication format data, specified material, delivery time, and cost. It is assumed that as the specified material, a material is directly specified in some cases, whereas in some other cases the material is specified by its texture (such as surface gloss or hardness), outward appearance (such as transparency), or other features.
At the next step 106, the material/fabrication method compatibility table is read, and operating information on the three-dimensional fabricator 36 is read. Then, a fabrication method is selected by taking delivery time and cost into account. The process then transfers to step 108.
At step 108, the fabrication workflows N for performing composite fabrication are developed. That is, in the case of the composite fabrication unit 40 illustrated in
At the next step 110, a variable N representing a number given to a workflow is set to 1. Then, the process transfers to step 112 where, as a preparatory process, the three-dimensional fabricator 36 corresponding to the selected fabricated method is attached to the head holder 44, and then the process transfers to step 114.
At step 114, operation of the belt conveyor 38 (moving table) is controlled. Specifically, each fabricating location on the belt conveyor 38 is so positioned as to face the corresponding three-dimensional fabricator 36 employed for the the workflows N (1 to n).
At the next step 116, a composite fabrication process is executed in accordance with a procedure indicated by the the workflows N, and then the process transfers to step 118.
At step 118, N is incremented (N←N+1). Then, at step 120, N and n are compared to determine whether N is greater than n. In the determination at step 120 is negative (Nn), it is determined that there are still remaining workflows N, and the process returns to step 114 to repeat the above-mentioned process.
If the determination at step 120 is affirmative (N≥n), it is determined that composite fabrication has finished, and this routine is ended.
The fabricated object manufacturer 32 delivers the finished three-dimensional fabricated object to the orderer. This completes the series of steps for fabricating the three-dimensional fabricated object.
Modification 1
The foregoing description of the exemplary embodiment is directed to a composite fabrication system in which the belt conveyor 38 is moved, and based on an already-fabricated component fabricated prior to this movement, another component is fabricated by the three-dimensional fabricator 36 that exists at a location to which the belt conveyor 38 is moved. In an alternative exemplary embodiment, as illustrated in
Modification 2
The foregoing description of the exemplary embodiment and Modification 1 is directed to a case where, as with each of the belt conveyor 38 serving as a table and the rotary table 38A, components 49A and 49B to be sequentially fabricated are moved. In an alternative exemplary embodiment, as illustrated in
The foregoing description of the exemplary embodiment of the present invention has been provided for the purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise forms disclosed. Obviously, many modifications and variations will be apparent to practitioners skilled in the art. The embodiment was chosen and described in order to best explain the principles of the invention and its practical applications, thereby enabling others skilled in the art to understand the invention for various embodiments and with the various modifications as are suited to the particular use contemplated. It is intended that the scope of the invention be defined by the following claims and their equivalents.
Number | Date | Country | Kind |
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2017-042835 | Mar 2017 | JP | national |