CN101489764A - 用于制作有形物体的***和方法 - Google Patents
用于制作有形物体的***和方法 Download PDFInfo
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- B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
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- G05B19/23—Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form characterised by positioning or contouring control systems, e.g. to control position from one programmed point to another or to control movement along a programmed continuous path using an incremental digital measuring device for point-to-point control
- G05B19/231—Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form characterised by positioning or contouring control systems, e.g. to control position from one programmed point to another or to control movement along a programmed continuous path using an incremental digital measuring device for point-to-point control the positional error is used to control continuously the servomotor according to its magnitude
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Abstract
一种用于制作有形物体的***。该***具有可充满液体的空间。基准平台至少部分地限定了所述空间的至少一侧。该***还具有相变换器,其可以通过选择性地将所述空间的预定区域中的液体变换成固体来形成所述物体的一层。致动器可以通过使所述层相对于所述基准平台进行移动或者使所述基准平台相对于所述层进行移动而将所述层与所述基准平台分离。该***具有控制器,其通过致动器控制输出端连接到所述致动器和/或通过变换器控制输出端连接到所述相变换器。所述控制器可以根据施加在所述基准平台上或所述固体上的力或与该力有关的参数的确定值来控制所述物体的制作。
Description
技术领域
本发明涉及用于制造诸如有形模型的有形三维物体的***和方法。
背景技术
在分层制造技术(LMT)(通常称为快速成型(RP)或快速制造(RM))领域中制作有形物体是公知的。快速成型(RP)或快速制造(RM)被称为“快速”,是因为它们不需要设计和制造模具。
LMT技术的一个例子是光固化成型法(SLA)。在SLA中,通过将连续的液态树脂层固化成合适的形状和尺寸来制作物体。SLA包括激光器,该激光器用于通过在一槽可光致固化的树脂的表面上方移动激光束来将一层固化成期望的形状和尺寸。对激光束在该表面上方的移动进行控制,使之对应于所设计的要制作的物体的3D数字模型的CAD/CAM切片图案。因此,树脂被固化成该3D数字模型的各个切片图案的形状。在每个固化步骤后,都将支撑要制作的物体的制造平台降低到槽中的液面以下。液态树脂会流到物体的顶面上方,从而形成新的树脂层。随后,可以对应于另一CAD/CAM切片图案来固化这个新的树脂层。
然而,SLA的缺点是制作物体所需要的时间段较长。SLA低速的原因是激光器必须“写”切片图案。特别是在需要大表面时,这相对来讲是比较耗时的。SLA的另一缺点是,在将物体降低到液面以下后,需要很长时间使树脂稳定并平直,因此形成一个新的树脂层要花费相对长的时间。
在LMT技术中还公知一种由德国的Envision Technologies GmbH出售的名为“Perfactory”的设备,该设备消除了SLA的缺点。该设备采用汞灯与微镜阵列的组合来代替激光器,将期望的切片图案投射到可光致固化的树脂的表面。因此,几乎同时对一层树脂进行了光固化,因而比用激光束来写图案要快。
Perfactory还通过覆盖了透明的类似橡胶的(硅树脂)抗粘薄膜的透明玻璃板,从下方对树脂槽进行照射。在进行了固化后,借助自动牵引将玻璃板从刚固化了的层上移开,液态树脂在玻璃板和刚固化了的层之间的空间内流动,由此形成要固化的下一层。因此,树脂层流入刚固化了的层与玻璃板之间的空间后通过该空间而稳定并平直,因此比SLA所花费的时间要短。
然而,SLA和Perfactory的一个共同缺点在于,制造物体需要花费相对长的时间。典型地,制作大约25-150微米的固化树脂层的周期为大约15到40秒。因此,制作大约20厘米的小物体需要花费大约20到40小时。
发明内容
本发明的一个目的是加快有形物体的制作。因此,根据本发明的第一方面,提供了一种根据权利要求1所述的***。而且,根据本发明的第二方面,提供了一种根据权利要求17所述的控制器。根据本发明的第三方面,提供了一种根据权利要求18所述的方法。根据第四方面,提供了一种根据权利要求20所述的计算机程序产品。
因为可以根据施加在基准平台上或固体上的力或与该力有关的参数来确定制造中的动作的适当时段或时刻,所以能更快地制作物体。因此,无需对所有层使用相同的预设时段或时刻,并且可以针对特定层来调整制作一层所需的时间段。因此,可以缩短制作物体所需的时段。物体能造得更快的第二个原因在于,可以提高载物平台与基准平台之间的相对移动速度并对其进行优化从而适合要制造的物体的特定几何结构和材料。
所附权利要求中阐述了本发明的具体实施方式。
参考下文描述的实施方式,本发明的这些和其他方面将是显然的并得到了阐明。
附图说明
下面将参照附图仅通过举例的方式来描述本发明的更多细节、方面和实施方式。
图1示意性地示出了根据本发明的***的实施方式的例子的侧剖视图。
图2示意性地示出了在常规设备中形成一层的周期内基准平台与正在形成的物体之间的压力的测量值的例子。
图3示意地示出了适合于图1的例子的控制器的框图。
具体实施方式
图1示出了用于制作有形物体的***1的例子。在该图中,示出了制作中的物体5。有形物体5例如可以是制品的原型或模型或者其他适当类型的物体。如图1所示,***1可以包括槽2,槽中可以提供液体。在图1的例子中,槽2包括其中可填充有液体的空间3,以形成可被转化成固体层的液体层。空间3的至少一侧30由基准平台4至少部分地限定。在该例中,基准平台4限定了空间3的底侧。
然而,也可以是基准平台4限定了空间3的顶侧。在该例中,基准平台4包括抗粘层40,如类似橡胶的层或硅树脂层,该抗粘层形成了所述空间的壁并阻止层50粘到基准平台4上,由此易于分离层50。
***1还包括相变换器6。相变换器6可以通过选择性地将空间3中的液体变换成空间3中预定区域中的固体来形成物体5的层50。因此,可以获得期望尺寸和形状的固体层。
***1包括致动器8,该致动器可以相对于基准平台4来移动层50,或者相对于层50来移动基准平台4。由此,例如,层50可与基准平台4分离,或者将基准平台4与分离的层50之间的空间3形成为例如,使得基准平台4与分离的层50之间的距离适于获得期望厚度的下一层。例如,在图1的例子中,正在制作的物体5被悬挂在载物平台10上。通过使载物平台10朝向或远离空间3移动,物体5和层50可以朝向基准平台4移动或与基准平台4分离。起初,在开始制作物体时,载物平台10限定了空间3的与基准平台4所限定的侧30相对的相对侧。一旦形成了一个或多个层50-53,堆叠的层50-53的外层50(图1中的最下层50)就限定了该相对侧。在图1的例中,载物平台10被设置在空间3的相对(顶)侧并且基准平台4限定了该空间的底侧30。例如可以使载物平台10向上移动和/或使基准平台向下移动,以将层50与基准平台4分离开。
***1可以执行一种用于制作有形物体的方法的例子。该方法例如可以包括形成预定形状的连续层50-53。例如,可以通过将空间3充满液体并将空间3中的液体变换为空间3中的与所述预定形状相对应的预定区域中的固体来形成层50-53。由此可以形成各个层50-53。然后,可以通过将基准平台4从层50移开,来将该固体与该平台分离。形成层50后,可以重复该循环以形成下一层。例如,例如可以按照图1的例子中的向上的方式将该固体层从基准平台4上移开,以创建其中可以形成下一层的空间,并且可以在与物体5的下一层的期望形状和尺寸相对应的预定区域内重复相变换和分离的循环。
***1还包括控制器7。致动器8和相变换器6连接到控制器7的各个控制器输出端71、72。控制器7可以根据施加在基准平台4或层50上的力的确定值或根据与该力有关的参数(例如,正在形成的层50的加速度或形状和/或表面积),来控制物体5的制作。该确定值可以按任意适当的方式来确定。例如,控制器7可以接收来自传感器9的测量值。例如,在图1的例子中,控制器7通过控制器输入端70连接到力传感器9。力传感器可以测量相对于物体5施加在基准平台4上的力并将力的测量值输出到控制器7。根据该测量值,控制器例如可以对致动器8或相变换器6进行控制。
然而,也可以是这样,控制器7不接收测量值,而是接收根据例如对固体(例如物体5)或基准平台4施加的力的建模以及要形成的层的期望形状和尺寸而确定的值。例如,控制器7可以包括存储了建模的存储器,并且例如从可通信地连接到该控制器的计算机接收表示该物体的3D数字建模的切片的数据。该数据随后可以被输入到该力建模中,例如作为时间的函数来计算力,并根据计算出的力来控制***1。
***1与上述常规***相比提高了制作速度,这是因为控制器7可以根据施加在基准平台4或固体层上的力或者与该力有关的参数(例如,正在形成的层50的加速度或形状和/或表面积)的确定值,来控制物体5的制作,以下将更详细地进行描述。现有技术的***对每个子过程都采用了预设时间,此外还在如图2中用箭头w1、w2表示在两个子过程之间预设了等待时间,以保证各个子过程在开始下一子过程之前已经完成。因此,需要相对大量的时间来制作出一层。通过根据施加在基准平台4或固体上的力或者与该力有关的参数的确定值来控制***1,可以简单地确定或预测子过程完成或将要完成的时间,因此,可针对特定层调整子过程的时间段。
图2示意地示出了常规设备中在形成一层的周期中测得的基准平台与正在形成的物体之间的力的曲线图。在图2中,箭头I表示相变换过程,在此期间,例如,可以在空间3的液体上投射期望的辐射图案,以激发在对应于期望图案的预定区域内产生固相层的化学或物理过程。一旦获得了固相层50,就在图2中用箭头P表示的分离子过程中将层50与基准平台4分离开。此后,在用箭头M表示的子过程中,例如,通过将层50在图1中朝上移动并将基准平台定位在与分离阶段P之前相同的位置上,将空间3设为期望的尺寸。
如图2中用箭头100-102所表示的,在该常规***中,由于子过程的预设时段,该***在周期的大量时间内是空闲的,以保证例如基准平台4与层50的良好分离或保证空间3完全充满液体。因此,通过根据所确定的力来控制***1,可以缩短这种空闲时间。可以相信,由于控制器7的存在,制作单层的周期的所需的时段可以缩短大约50%,例如花费小于10秒的时间。
控制器7例如可以控制相变换器在预定时间内(例如根据要变换成固体的层50的厚度)对空间3中的液体进行固化,例如固化液态树脂。此后,通过利用致动器8将基准平台4从层50移开来将固化的层50与基准平台4分离。该分离可以由控制器7来控制。例如,控制器7可以接收测量值并将该值与存储在控制器7的存储器中的基准值进行比较。一旦确定该力变为基准值(例如零)以下,就终止该分离并可由控制器7开始子过程M。(就此而言,如果力变为零,当然,加速度变为零且速度变为恒定,则这种参数也可以用于控制***1。)而且,子过程M在力变为零的情况下会终止,并开始下一层的相变换,这是由于认为液体已经充分充满了所述空间。例如,在分离过程中,致动器8可以在控制器7的控制下将基准平台4从形成的层50上移开。在子过程M中,基准平台4可以向形成的层移动,以将形成的层50与基准平台4之间的空间3的宽度设为合适的值。
如上所述,通过测量(例如所说明的,利用力传感器)或通过计算预测(例如所说明的,利用力的预测建模)来确定施加在基准平台或固体上的力或与该力有关的参数的值。
然而,确定所述值的其他方法也是可行的。现在来说明这些其他方法的例子,其中,例如,要确定的所述值是早先讨论过的基准值(例如零),其表明可以终止分离子过程P并开始子过程M以缩短空闲时间。可以通过不同的适当技术进行所述基准值的确定,例如基于液体间隙或该***的几何学上的相关部分的位置的光学测距。另一种这样的技术可以基于通过载物平台引入振动并结合测量基准平台中引起的振动(反之亦然),以通过这种振动测量来检测基准平台与固化的层之间的连接的实质性变化。
应该注意,如上所述的两种或更多的这样不同的确定技术(测量;计算预测;诸如光学或振动相关的其他技术)可以在用于制作有形物体的单个***中或者一种制造有形物体的方式中进行彼此组合。
控制器7可以按照任意合适的方式来实现。例如,图3中的控制器的例子包括第一比较器73,其通过比较器输入端731连接到控制器输入端70并通过另一比较器输入端732连接到存储有适当基准值的存储器730。第一比较器通过比较器输出端733连接到致动器控制单元74。第一比较器73将在控制器输入端70处接收到的测量值与存储在存储器730中的基准值进行比较。根据比较结果,经由比较器输出端733向致动器控制器74发送一信号。响应于该信号,致动器8将基准平台4从层50移开或停止该移动。接着,致动器控制器可以使基准平台4开始朝向层50回移。一旦基准平台4移动到初始位置,基准平台4就保持不动。
图3中的控制器7的例子还包括第二比较器76,其通过比较器输入端761连接到控制器输入端70并通过另一比较器输入端762连接到存储有适当基准值的存储器760。第二比较器76通过比较器输出端763连接到定时器77、相变换器控制单元75和致动器控制单元74。一旦基准平台4移回到初始位置,第一比较器76就将在控制器输入端70处接收到的测量值与存储在存储器760中的基准值进行比较。根据比较结果,经由比较器输出端763向定时器77和相变换器控制器75发送一信号,以启动定时器和激活控制器75。基准值例如可以表示零牛顿的力。不希望受限于任何理论,我们认为一旦基准平台4回到其初始位置,基准平台4与形成的层50之间的空间3中的液体就会在某一时段内持续流动并对基准平台4和形成的层50(即,***的限定了该空间的部分)施加力。液体例如可以继续流出空间3而进入槽2中。一旦液体停止流动,力就变为零。因此,第二比较器76通过将测量值与对应于零的阈值进行比较,可以针对特定层精确地确定液体停止流动的时刻,因此缩短了空闲时间。一旦液体停止流动,就可以由相变换控制器75启动空间3中的液体的相变换并启动定时器77。
该控制器还可以包括连接到控制输入端和存储器的比较器,该存储器存储有力阈值,该力阈值用于将移动或移动的速度限制到某一阈值,以将作用在物体5上的力保持在损伤阈值以下,因此减少了损伤物体的机会。例如,如图2所示,在分离期间会出现峰力。通过控制致动器,使得参数值保持在对应于峰力的值以下,可以防止对物体的损伤或至少减少这种损伤的风险。
传感器可以按照任意适当的方式来实施。传感器例如可以包括用于测量平行于或相对于层或基准平台的移动方向的力的力传感器。传感器可以包括三点测力***。由此可以获得力的精确测量。
基准平台4可以由致动器8以任意适当的方式移动。基准平台4例如可以相对于层进行枢转,以至少部分地将基准平台与层分离。然而,基准平台4也可以沿直线移动而不旋转或以任意其他适于将平台与层分离或在基准平台与层之间提供其中可以制作物体的下一层的空间的方式来移动。
相变换器6可以利用任意适当的化学或物理过程将空间3中的液体变换成固体。变换器6例如可以激发液体中的成分的化学反应,该化学反应得到了固体反应产物。例如,槽可以包含可被电磁辐射固化的液体树脂,例如光致聚合物,可通过投射适当波长的光来激发其聚合。
可以通过适当类型的能量将液体变换成固体,并且相变换器可以包括能量源,该能量源选择性地将能量提供到所述预定区域。该能量源例如可以包括电磁辐射源。在图1的例子中,例如,相变换器6包括可以发光的光源60,光经由投射单元61以对应于层50的期望形状和尺寸的图案投射在空间3中。为了使光或其他辐射能够进入空间3,基准平台4可以包括对于辐射透明的窗口。
本发明还可以实现为运行在计算机***上的计算机程序,至少包括在可编程设备(如计算机***)上运行时用于执行根据本发明的方法的步骤或使可编程设备执行根据本发明的装置或***的功能的代码部分。这种计算机程序可以设置在存储有可载入计算机***的存储器中的数据的数据载体(如CD-ROM或磁盘)上,该数据代表了所述计算机程序。数据载体还可以是数据连接,如电话线或无线连接。
在之前的说明书中,参照本发明的具体实施例描述了本发明。然而,在不偏离所附权利要求所阐述的本发明更宽泛的精神和范围的情况下在此作出各种改变和变化是显而易见的。例如,槽可以比图1所示的槽更高或更低。而且,物体可以为任意适当尺寸和形状。
而且,本发明不限于以不可编程硬件实现的物理装置或单元,而是还可以应用于可以通过运行根据适当程序代码而执行期望的装置功能的可编程装置或单元。此外,所述装置可以物理地分布为多个设备,而功能上作为单个装置而工作。例如,控制器7可以包括充当致动器控制单元74的单独设备以及充当相变换器控制单元75的另一设备。
而且,功能上形成为分离装置的装置可以集成为单个物理装置。例如,控制器7可以实现为单个集成电路。
然而,其他改变、变化或替换也是可能的。因此,说明书和附图可以看作为解释性的,而不是限制性的。
在权利要求中,放置在括号间的任何附图标记都不应理解为对权利要求的限制。词语“包括”不排除存在权利要求所列的部件和步骤之外的其他部件和步骤。而且,词语“一”和“一个”不应被理解为限制于“仅一个”,而是用于表示“至少一个”,并不排除多个。在互不相同的权利要求中陈述的特定方式并不意味着就不能利用这些方式的组合。
Claims (20)
1、一种用于制作有形物体的***,该***包括:
可充满液体的空间;
至少部分地限定所述空间的至少一侧的基准平台;
相变换器,用于通过选择性地将所述空间的预定区域中的液体变换成固体来形成所述物体的层;
致动器,用于通过使所述层相对于所述基准平台进行移动或者使所述基准平台相对于所述层进行移动而将所述层与所述基准平台分离;以及
控制器,其通过致动器控制输出端连接到所述致动器和/或通过变换器控制输出端连接到所述相变换器,用于根据施加在所述基准平台上或所述固体上的力或与该力有关的参数的确定值来控制所述物体的制作。
2、根据权利要求1所述的***,该***还包括:
传感器,用于感测所述力或与所述力有关的参数,并且
其中所述控制器通过控制输入端连接到所述传感器,用于接收所述确定值。
3、根据权利要求2所述的***,其中所述传感器包括:力传感器,用于测量平行于或相对于所述层或所述基准平台的移动方向的力。
4、根据权利要求2或3所述的***,其中所述传感器包括三点测力***。
5、根据以上任意一项权利要求所述的***,其中所述控制器被设置成根据所述力的值来确定制造所述物体的子过程的合适时间,所述子过程例如是用于将所述层与所述基准平台分离的子过程和/或用于将所述液体变换成固体的子过程和/或用于形成所述物体的下一层的循环的子过程。
6、根据以上任意一项权利要求所述的***,其中所述控制器包括:定时器,用于根据作为时间函数的所述值来控制所述致动器。
7、根据以上任意一项权利要求所述的***,其中所述控制器包括:连接到所述控制输入端和存储有力阈值的存储器的比较器,用于在所述确定值超过了该力阈值的情况下限制所述移动或所述移动的速度。
8、根据权利要求7所述的***,其中所述力阈值被存储为时间的函数。
9、根据以上任意一项权利要求所述的***,其中所述基准平台可以相对于所述层进行枢转,以至少部分地分离所述基准平台和所述层;并且/或者所述层可以在远离所述基准平台的方向上移动,从而在所述基准平台与所述层之间提供可以制作所述物体的下一层的空间。
10、根据以上任意一项权利要求所述的***,该***还包括:
存储有作用在所述层或所述基准平台上的力的建模的存储器,其中所述控制器包括用于接收适于输入到所述建模中以确定所述力的数据的控制输入端。
11、根据以上任意一项权利要求所述的***,该***还包括:
载物平台,其限定了所述空间的与所述平台所限定的侧相对的一侧,所述层可以被悬挂到所述载物平台上,以使所述层相对于所述基准平台进行移动;并且
其中所述致动器可以使所述载物平台相对于所述基准平台进行移动,以将悬挂在所述载物平台上的层与所述基准平台分离。
12、根据权利要求11所述的***,其中所述载物平台提供了所述空间的顶侧而所述基准平台限定了所述空间的底侧,并且所述载物平台向上移动和/或所述基准平台向下移动以将所述层与所述基准平台分离。
13、根据以上任意一项权利要求所述的***,其中所述基准平台包括诸如类似橡胶层或硅树脂层的抗粘层,其形成了所述空间的壁。
14、根据以上任意一项权利要求所述的***,其中可以通过适当类型的能量将所述液体变换成固体,并且所述相变换器包括能量源,该能量源选择性地将能量提供给所述预定区域。
15、根据以上任意一项权利要求所述的***,其中:
所述能量源包括电磁辐射源;
所述基准平台包括对于所述辐射透明的窗口;并且所述***还包括投射单元,用于通过所述窗口将电磁辐射投射到所述预定区域。
16、根据以上任意一项权利要求所述的***,其中所述相变换器可以激发所述液体中的成分的得到固体反应产物的化学反应,诸如通过电磁辐射使液态树脂固化。
17、一种用于根据以上任意一项权利要求所述的***的控制器。
18、一种用于制作有形物体的方法,该方法包括形成预定形状的至少一层,所述形成包括以下步骤:
提供充满液体的空间,该空间的至少一侧至少部分地由一平台限定;
在所述空间的与所述预定形状相对应的预定区域中将所述液体变换成固体;
通过使所述平台相对于所述空间的另一侧进行移动或者使所述空间的另一侧相对于所述平台进行移动,将所述固体与所述平台分离;
其中根据施加在所述平台上或所述固体上的力或与该力有关的参数的确定值来控制所述制作。
19、根据权利要求18所述的方法,该方法还包括以下步骤:通过在所述分离的固体与所述平台之间提供空间、用液体充满所述分离的固体与所述平台之间的所述空间并重复所述变换步骤和分离步骤,来形成预定形状的下一层。
20、一种包括程序代码部分的计算机程序产品,所述程序代码部分在可编程设备上运行时用于执行根据权利要求17所述的控制器的功能。
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Also Published As
Publication number | Publication date |
---|---|
CA2656993A1 (en) | 2008-01-10 |
EP1876012A1 (en) | 2008-01-09 |
JP2009542484A (ja) | 2009-12-03 |
DE602007009991D1 (de) | 2010-12-02 |
CA2656993C (en) | 2014-09-09 |
JP4837097B2 (ja) | 2011-12-14 |
WO2008004872A1 (en) | 2008-01-10 |
ES2354918T3 (es) | 2011-03-21 |
CN101489764B (zh) | 2012-01-11 |
ATE485156T1 (de) | 2010-11-15 |
US20090289384A1 (en) | 2009-11-26 |
EP2043845A1 (en) | 2009-04-08 |
EP2043845B1 (en) | 2010-10-20 |
US9205599B2 (en) | 2015-12-08 |
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