PROCESSING SYSTEM

A processing system includes: a processing apparatus for processing an object; a rotation apparatus for rotating a holding part holding the object; a movement apparatus for moving at least one of the processing apparatus and the holding part; a measurement apparatus for measuring at least a part of the object held by the holding part; and a control apparatus for controlling the movement apparatus and the rotation apparatus based on a measured result by the measurement apparatus to rotate the holding part and to move at least one of the processing apparatus and the holding part

TECHNICAL FIELD

The present invention relates to a processing system that is configured to process an object, for example.

BACKGROUND ART

A Patent Literature 1 discloses a processing system that is configured to process an object. The technical problem of the processing system is to properly process the object.

CITATION LIST

Patent Literature

SUMMARY OF INVENTION

A first aspect provides a processing system that is configured to process an object, wherein the processing system includes: a processing apparatus that is configured to process the object; a rotation apparatus that is configured to rotate a holding part that holds the object; a movement apparatus that is configured to move at least one of the processing apparatus and the holding part; a measurement apparatus that is configured to measure at least a part of the object held by the holding part; and a control apparatus that is configured to control the movement apparatus and the rotation apparatus based on a measured result by the measurement apparatus to rotate the holding part and to move at least one of the processing apparatus and the holding part.

A second aspect provides a processing system that is configured to process an object, wherein the processing system includes: a processing apparatus that is configured to process the object by irradiating the object with an energy beam; a movement apparatus that is configured to move at least one of an irradiation position of the energy beam and the object; a rotation apparatus that is configured to rotate a holding part that holds the object; a measurement apparatus that is configured to measure at least a part of the object; and a control apparatus that is configured to control the movement apparatus and the rotation apparatus based on a measured result by the measurement apparatus to rotate the object and to move at least one of the irradiation position and the object.

A third aspect provides a processing system that is configured to process an object, wherein the processing system includes: a processing apparatus that is configured to process the object; a rotation apparatus that is configured to rotate a holding part that holds the object; a movement apparatus that is configured to move at least one of the processing apparatus and the holding part; a measurement apparatus that is configured to measure at least a part of the object held by the holding part; and a control apparatus that is configured to obtain a relationship between the object held by the holding part and a rotational axis of the rotation apparatus based on a measured result by the measurement apparatus.

A fourth aspect provides a processing system that is configured to process an object, wherein the processing system includes: a processing apparatus that is configured to process the object; a holding part that includes: a first surface on which the object is placed; and a second surface that is different from the first surface; and a cooling apparatus that is configured to cool the second surface.

A fifth aspect provides a processing system that is configured to process an object, wherein the processing system comprises: a processing apparatus that is configured to process the object; a holding part that includes: a first surface on which the object is placed; and a second surface that is different from the first surface; and a gas supply apparatus that is configured to supply a gas to a space facing the second surface.

An operation and another advantage of the present invention will be apparent from an example embodiment described below.

DESCRIPTION OF EMBODIMENTS

Next, with reference to drawings, a processing system SYS that is one example embodiment of a processing system will be described. In the below described description, a positional relationship of various components that constitute the processing system SYS will be described by using an XYZ rectangular coordinate system that is defined by a X axis, a Y axis and a Z axis that are perpendicular to one another. Note that each of an X axis direction and a Y axis direction is assumed to be a horizontal direction (namely, a predetermined direction in a horizontal plane) and a Z axis direction is assumed to be a vertical direction (namely, a direction that is perpendicular to the horizontal plane, and substantially an up-down direction or a gravity direction), for the purpose of simple description, in the below described description. Moreover, rotational directions (in other words, inclination directions) around the X axis, the Y axis and the Z axis are referred to as a θX direction, a θY direction and a θZ direction, respectively. Here, the Z axis direction may be the gravity direction. An XY plane may be a horizontal direction.

(1) Processing System SYS in First Example Embodiment

Firstly, the processing system SYS in a first example embodiment (in the below described description, the processing system SYS in the first example embodiment is referred to as a “processing system SYSa”) will be described. The processing system SYSa in the first example embodiment is a processing system that is configured to form the three-dimensional structural object ST by performing an additive processing. The processing system SYSa is configured to form the three-dimensional structural object ST by performing the additive processing based on a LMD (Laser Metal Deposition), for example. Note that the Laser Metal Deposition may be referred to as a Direct Metal Deposition, a Direct Energy Deposition, a Laser Cladding, a Laser Engineered Net Shaping, a Direct Light Fabrication, a Laser Consolidation, a Shape Deposition Manufacturing, a Wire Feed Laser Deposition, a Gas Through Wire, a Laser Powder Fusion, a Laser Metal Forming, a Selective Laser Powder Re-melting, a Laser Direct Casting, a Laser Powder Deposition, a Laser Additive Manufacturing or a Laser Rapid Forming. However, the processing system SYSa may be configured to form the three-dimensional structural object ST by performing the additive processing based on another additive processing method.

Next, a configuration and operation of the processing system SYSa performing the additive processing will be described in sequence.

(1-1) Configuration of Processing System SYSa

Firstly, with reference toFIG.1toFIG.3, a configuration of the processing system SYSa in the first example embodiment will be described.FIG.1is a system configuration diagram that illustrates a system configuration of the processing system SYSa. Each ofFIG.2andFIG.3is a cross-sectional view that conceptionally illustrates the configuration of the processing system SYSa in the first example embodiment.

The processing system SYSa is configured to form the three-dimensional structural object ST (namely, a three-dimensional object having a size in each of three-dimensional directions, a solid object, in other words, an object having a size in the X axis direction, the Y axis direction and the Z axis direction). The processing system SYSa is configured to form the three-dimensional structural object ST on a workpiece W that is a base (namely, a base member) for forming the three-dimensional structural object ST. The processing system SYSa is configured to form the three-dimensional structural object ST on the workpiece W by performing the additive processing on the workpiece W. When the workpiece W is a below described stage31, the processing system SYSa may be configured to form the three-dimensional structural object ST on the stage31. When the workpiece W is a placed object that is placed on the stage31, the processing system SYSa may be configured to form the three-dimensional structural object ST on the placed object. In this case, the processing system SYSa may form the three-dimensional structural object ST that is integrated with the placed object. An operation for forming the three-dimensional structural object ST that is integrated with the placed object may be regarded to be equivalent to an operation for adding a new structural object to the placed object. Alternatively, the processing system SYSa may form the three-dimensional structural object ST that is separable from the placed object. The placed object that is placed on the stage31may be another three-dimensional structural object ST (namely, an existing structural object) that is formed by the processing system SYSa. The below described description uses the example in which the workpiece W is the placed object placed on the stage31.

As described above, the processing system SYSa is configured to form the three-dimensional structural object ST by the Laser Metal Deposition. Namely, it can be said that the processing system SYSa is a 3D printer that forms an object by using an Additive layer manufacturing technique. Note that the Additive layer manufacturing technique may be referred to as a Rapid Prototyping, a Rapid Manufacturing or an Additive Manufacturing.

The processing system SYSa forms a build object by processing build materials M by a processing light EL. The build material M is a material that is molten by an irradiation of the processing light EL having a predetermined intensity or more intensity. At least one of a metal material and a resin material is usable as the build material M, for example. However, another material that is different from the metal material and the resin material may be used as the build material M. The build materials M are powder-like or grain-like materials. Namely, the build materials M are powdery and granular materials. However, the build materials M may not be the powdery and granular materials. For example, wired-like build materials or gas-like build materials may be used as the build materials M.

In order to form the three-dimensional structural object ST, the processing system SYSa includes a material supply source1, a processing unit2, a stage unit3, a measurement apparatus, a light source5, a gas supply source6and a control apparatus7, as illustrated inFIG.1toFIG.3. At least a part of the processing unit2, the stage unit3and the measurement apparatus4may be contained in an inner space of a housing8.

The material supply source1is configured to supply the build materials M to the processing unit2. The material supply source1supplies, to the processing unit2, the build materials M the amount of which is necessary for forming the three-dimensional structural object ST per unit time by supplying the build materials M the amount of which is based on the necessary amount.

The processing unit2is configured to form the three-dimensional structural object ST by processing the build materials M supplied from the material supply source1. In order to form the three-dimensional structural object ST, the processing unit2includes a processing head21and a head driving system22. Moreover, the processing head21includes an irradiation optical system211and a material nozzle212(namely, a supply system that is configured to supply the build materials M). Note that the processing head21may be referred to as a processing apparatus.

The irradiation optical system211is an optical system (for example, a condensing optical system) for emitting the processing light EL from an emitting part213. Specifically, the irradiation optical system211is optically connected to the light source5that generates the processing light EL through a light transmitting member51such as an optical fiber and light pipe. The irradiation optical system211emits the processing light EL transmitted from the light source5through the light transmitting member51. The irradiation optical system211emits the processing light EL in a downward direction (namely, toward a −Z side) from the irradiation optical system211. The stage31is disposed below the irradiation optical system211. When the workpiece W is placed on the stage31, the irradiation optical system211emits the processing light EL toward the workpiece W. Thus, the irradiation optical system211may be referred to as an irradiation apparatus. Specifically, the irradiation optical system211is configured to irradiate a target irradiation area EA, which is set on the workpiece W or near the workpiece W as an area that is irradiated with the processing light EL (typically, in which the light is condensed), with the processing light EL. Moreover, a state of the irradiation optical system211is switchable between a state where the target irradiation area EA is irradiated with the processing light EL and a state where the target irradiation area EA is not irradiated with the processing light EL under the control of the control apparatus7. Note that a direction of the processing light EL emitted from the irradiation optical system211is not limited to a direct downward direction (namely, coincident with the −Z axis direction), and may be a direction that is inclined with respect to the Z axis by a predetermined angle, for example.

A supply outlet is formed at the material nozzle212. The material nozzle212is configured to supply (specifically, inject, jet, blow out or spray) the build materials M from the supply outlet214. The material nozzle212is physically connected to the material supply source1, which is a supply source of the build materials M, through a supply pipe11and a mix apparatus12. The material nozzle212supplies the build materials M supplied from the material supply source1through the supply pipe11and the mix apparatus12. The material nozzle212may pressure-feed the build materials M supplied from the material supply source1through the supply pipe11. Namely, the build materials M from the material supply source1and a gas for feeding (namely, a pressure-feed gas, and an inert gas such as a Nitrogen or an Argon, for example) may be mixed by the mix apparatus12and then pressure-fed to the material nozzle212through the supply pipe11. As a result, the material nozzle212supplies the build materials M together with the gas for feeding. A purge gas supplied from the gas supply source6is used as the gas for feeding, for example. However, a gas supplied from a gas supply apparatus that is different from the gas supply source6may be used as the gas for feeding. Note that the material nozzle212is illustrated to have a tube-like shape inFIG.1, however, a shape of the material nozzle212is not limited to this shape. The material nozzle212supplies the build materials M in a downward direction (namely, toward the −Z side) from the material nozzle212. The stage31is disposed below the material nozzle212. When the workpiece W is placed on the stage31, the material nozzle212supplies the build materials M toward the workpiece W or a vicinity of the workpiece W. Note that a supply direction of the build materials M supplied from the material nozzle212is a direction that is inclined with respect to the Z axis by a predetermined angle (as one example, an acute angle), however, it may be the −Z axis direction (namely, a direct downward direction).

In the present example embodiment, the material nozzle212is aligned to the irradiation optical system211so as to supply the build materials M to the target irradiation area EA that is irradiated with the processing light EL by the irradiation optical system211. Namely, the material nozzle212is aligned to the irradiation optical system211so that the target irradiation area EA is coincident with (alternatively, at least partially overlaps with) a target supply area MA that is set on the workpiece W or near the workpiece W as an area to which the material nozzle212supplies the build materials M. Note that the material nozzle212may be aligned to the irradiation optical system211so that the material nozzle212supplies the build materials M to a melt pool MP (described below) that is formed by the processing light EL emitted from the irradiation optical system211. Note that the material nozzle212may not supply the materials to the melt pool MP. For example, the processing system SYSa may melt the build materials by the irradiation optical system211before the build materials M from the material nozzle212reaches the workpiece W, and may make the molten build materials M adhere to the workpiece W.

The head driving system22is configured to move the processing head21. Thus, the head driving system22may be referred to as a movement apparatus. The head driving system22moves the processing head21along at least one of the X axis, the Y axis, the Z axis, the θX direction, the θY direction and the θZ direction, for example. In an example illustrated inFIG.2andFIG.3, the head driving system22moves the processing head21along each of the X axis, the Y axis and the Z axis. In this case, the head driving system22may include a head driving system22X, a head driving system22Y and a head driving system22Z. The head driving system22X is configured to move the processing head21along the X axis. The head driving system22Y is configured to move the processing head21along the Y axis. The head driving system22Z is configured to move the processing head21along the Z axis

The head driving system22X includes: a Y guide member221Y that is connected to a support frame224, which is disposed on a bottom surface of the housing8(alternatively, a surface plate disposed on the bottom surface of the housing8) through a vibration isolator such as an air spring, and that extends along the Y axis; a Y slide member222Y that is movable along the Y guide member221Y; and a non-illustrated motor that moves the Y slide member222Y. The head driving system22Y includes: a X guide member221X that is connected to the Y slide member222Y and that extends along the X axis; a X slide member222X that is movable along the X guide member221X; and a non-illustrated motor that moves the Y slide member222X. The head driving system22Z includes: a Z guide member221Z that is connected to the X slide member222X and that extends along the Z axis; a Z slide member222Z that is movable along the Z guide member221Z; and a non-illustrated motor that moves the Z slide member222Z. the processing head21is connected to the Z slide member222Z. When the Y slide member222Y moves along the Y guide member221Y, the processing head21that is connected to the Y slide member222Y through the head driving systems22X and22Z moves along the Y axis. When the X slide member222X moves along the X guide member221X, the processing head21that is connected to the X slide member222X through the head driving system22Z moves along the X axis. When the Z slide member222Z moves along the Z guide member221Z, the processing head21that is connected to the Z slide member222Z moves along the Z axis.

When the head driving system22moves the processing head21, a relative position between the processing head21and each of the stage31and the workpiece W placed on the stage31changes. Namely, a relative position between each of the irradiation optical system211and the material nozzle212(the supply outlet214) and each of the stage31and the workpiece W changes. Thus, the head driving system22may serve as a position change apparatus that is configured to change the relative positional relationship between each of the irradiation optical system211and the material nozzle212(the supply outlet214) and each of the stage31and the workpiece W. Furthermore, when the relative position between the processing head21and each of the stage31and the workpiece W changes, the target irradiation area EA and the target supply area MA (furthermore, the melt pool MP) relatively moves relative to the workpiece W. Thus, the head driving system22may serve as a movement apparatus that is configured to relatively move the target irradiation area EA and the target supply area MA (furthermore, the melt pool MP) relative to the workpiece W.

The stage unit3includes the stage31, a stage driving system32and a position measurement device33. Note that the stage31may be referred to as a table.

The stage31is configured to support the workpiece W. Note that a state where “the stage31supports the workpiece W” here may mean a state where the workpiece W is directly or indirectly supported by the stage31. The stage31may be configured to hold the workpiece W placed on the stage31. Namely, the stage31may support the workpiece W by holding the workpiece W. thus, the stage31may serve as a holding part that holds the workpiece W. Alternatively, the stage31may not be configured to hold the workpiece W. In this case, the workpiece W may be placed on the stage31without a clamp. Furthermore, the stage31may be configured to release the held workpiece W, when the workpiece W is held. The above described irradiation optical system211emits the processing light EL in at least a part of a period when the stage31supports the workpiece W. Furthermore, the above described material nozzle212supplies the build materials M in at least a part of the period when the stage31supports the workpiece W. Note that the stage31may include a mechanical chuck, a vacuum chuck and the like in order to hold the workpiece W.

In the present example embodiment, the stage31includes a stage31θX and a stage310Z. A reason why the stage31includes the stage31θX and the stage31θZ to move the stage31along each of the θX direction and the θZ direction by the below described stage driving system32, as described later in detail. The workpiece W is supported by the stage310Z. The stage31θX is movable along the θX direction (namely, rotatable around a rotational axis along the X axis) by the stage driving system32described later. The stage310Z is disposed in a concave part formed at the stage31θX so as to rotatable around the rotational axis along the X axis together with the stage31θX due to the rotation of the stage31θX. The stage31θZ is disposed in the concave part formed at the stage31θX so as to movable along the θZ direction (namely, rotatable around a rotational axis along the Z axis) by the stage driving system32independently from the rotation of the stage31θX. Note that a configuration of the stage31is not limited to a configuration illustrated inFIG.2andFIG.3. As one example, the stage31θZ may not be disposed in the concave part formed at the stage31θX.

The stage driving system32is configured to move the stage31. Thus, the stage driving system32may be referred to as a movement apparatus. The stage driving system32moves the stage31along at least one of the X axis, the Y axis, the Z axis, the θX direction, the θY direction and the θZ direction, for example. In the example illustrated inFIG.2andFIG.3, the stage driving system32moves the stage31along each of the θX direction and the θZ direction. Namely, the stage driving system32rotates the stage31around the rotational axis along the X axis and rotates the stage31around the rotational axis along the Z axis. Thus, the stage driving system32may be referred to as a rotation apparatus. In this case, the stage driving system32may include a stage driving system32θX and a stage driving system32θZ. The stage driving system32θX is configured to rotate the stage31(especially, the stage31θX) around the rotational axis along the X axis. The stage driving system32θZ is configured to rotate the stage31(especially, the stage31θZ) around the rotational axis along the Z axis. The stage driving system32θX includes a pair of rotational shafts321θX that is rotatably connected to a pair of support frames323, which is disposed on the bottom surface of the housing8(alternatively, the surface plate disposed on the bottom surface of the housing8) through a vibration isolator such as an air spring; and a motor322θX that rotates the pair of the rotational shafts321θX around the rotational axis along the X axis. The pair of the rotational shafts321θX extends along the X axis direction. The pair of the rotational shafts321θX is connected to the stage31θX so that the stage31is between them along the X axis direction. The stage driving system32θZ includes a rotational shaft321θZ that extends along the Z axis direction and that is connected to a bottom surface of the stage31θX (specifically, a surface facing the stage31θZ); and a motor322θZ that rotates the rotational shaft321θZ around the rotational axis along the Z axis. When the pair of the rotational shafts321θX rotates, the stage31θX rotates around a rotational axis along the X axis. As a result, the stage31θZ supported by the stage31θX (furthermore, the workpiece W supported by the stage31θZ) also rotates around the rotational axis along the X axis. When the rotational shafts321θZ rotates, the stage31θZ (furthermore, the workpiece W supported by the stage31θZ) also rotates around a rotational axis along the Z axis. Note that the stage31illustrated inFIG.2andFIG.3has a double-sided structure in which stage31θX is supported from both sides by support frame323. The stage31has a double-sided structure in which the stage31θX is supported from both sides by the support frame323. However, the stage31may have a cantilever structure in which the stage31θX is supported from one side by the support frame323.

When the stage driving system32moves the stage31, the relative position between the processing head21and each of the stage31and the workpiece W placed on the stage31changes. Namely, the relative position between each of the irradiation optical system211and the material nozzle212(the supply outlet214) and each of the stage31and the workpiece W changes. Thus, the stage driving system32may serve as a position change apparatus that is configured to change the relative positional relationship between each of the irradiation optical system211and the material nozzle212(the supply outlet214) and each of the stage31and the workpiece W. Furthermore, when the relative position between the processing head21and each of the stage31and the workpiece W changes, the target irradiation area EA and the target supply area MA (furthermore, the melt pool MP) relatively moves relative to the workpiece W. Thus, the stage driving system32may serve as a movement apparatus that is configured to relatively move the target irradiation area EA and the target supply area MA (furthermore, the melt pool MP) relative to the workpiece W.

The position measurement device33is configured to measure (in other words, is configured to detect) a position of the stage31. In the present example embodiment, since the stage31is rotatable as described above, the position measurement device33may be configured to measure the position of the stage31in a rotational direction. For example, the position measurement device33may include an angle detection apparatus (an angle detection part) that is configured to measure a rotational angle of the stage31. More specifically, the position measurement device33may be configured to measure a rotational angle of the stage31(especially, the stage31θX) around the rotational axis along the X axis and a rotational angle of the stage31(especially, the stage31θZ) around the rotational axis along the Z axis. An encoder is one example of the position measurement device33. Note that the position measurement device33may be embedded to the stage driving system32.

The measurement apparatus4is an apparatus that is configured to measure at least a part of a measurement target object. For example, the measurement apparatus4may be configured to measure a shape of at least a part of the measurement target object. For example, the measurement apparatus4may be configured to measure a position of at least a part of the measurement target object. A three-dimensional measurement device (in other words, a 3D scanner) is one example of the measurement apparatus. In this case, the measurement apparatus4may measure the measurement target object by using a Pattern Projection method or a Light Section method that irradiates a surface of the measurement target object with a measurement light ML to project a light pattern on the surface and measures a shape of the projected pattern. Alternatively, the measurement apparatus4may measure the measurement target object by using a Time Of Flight method that performs an operation, which emits a measurement light ML to the surface of the measurement target object and measures a distance to the object based on an elapsed time until the emitted measurement light ML returns, at plurality of positions on the object. Alternatively, he measurement apparatus4may measure the measurement target object by using at least one of a Moire Topography method (specifically, a grid illumination method or a grid projection method), a Holographic Interference method, an auto collimation method, a stereo method, an astigmatism method, a critical angle method and a knife edge method. Note that at least one of the workpiece W, the three-dimensional structural object ST (namely, the workpiece W integrated with the three-dimensional structural object ST), a below described structural layer SL forming the three-dimensional structural object ST (namely, the workpiece W integrated with the three-dimensional structural object ST) and the stage31is one example of the measurement target object.

The measurement apparatus4may be fixed to the support frame224. In this case, when the stage driving system32rotates the stage31, a relative positional relationship between the measurement apparatus4and each of the stage31and the workpiece W supported by the stage31changes. Especially, when the stage driving system32rotates the stage31, an angle between a measurement axis of the measurement apparatus4(for example, an optical axis of an optical system that is included in the measurement apparatus4to emit the measurement light ML) and the rotational axis of the stage31and the workpiece W supported by the stage31(namely, the rotational axis of the stage driving system32) changes. Therefore, the measurement apparatus4may serve as an angle change apparatus that is configured to change the angle between the measurement axis of the measurement apparatus4and the rotational axis of the stage driving system32. Note that the measurement apparatus4may be movable. For example, the measurement apparatus4may be movable along at least one of the X axis, the Y axis, the Z axis, the θX direction, the θY direction and the θZ direction. For example, the measurement apparatus4may be rotatable around at least one of a rotational axis along the X axis, a rotational axis along the Y axis and a rotational axis along the Z axis. When the measurement apparatus4is rotated, the angle between the measurement axis of the measurement apparatus4and the rotational axis of the stage driving system32changes. Note that the measurement apparatus4may be fixed to the housing8.

The light source5is configured to emit at least one of an infrared light, a visible light and an ultraviolet light as the processing light EL, for example. However, another type of light may be used as the processing light EL. The processing light EL may include plurality of pulsed lights (namely, a plurality of pulsed beam). The processing light EL may be a laser light. In this case, the light source5may include a semiconductor laser such as a laser light source (for example, a Laser Diode (LD)). The laser light source may be a fiber laser, a CO2laser, a YAG laser, an Excimer laser and the like. However, the processing light EL may not be the laser light. The light source5may include any light source (for example, at least one of a LED (Light Emitting Diode), a discharge lamp and the like).

The gas supply source6is a supply source of a purge gas for purging the inner space of the housing8. The purge gas includes inert gas. The Nitrogen gas or Argon gas is one example of the inert gas. The gas supply source6supplies the purge gas to the inner space of the housing through supply pipe61that connects the gas supply source6and the housing8. As a result, the inner space of the housing8is a space that is purged by the purge gas. Note that the gas supply source6may be a tank that stores the inert gas such as the Nitrogen gas or the Argon gas. When the purge gas is the Nitrogen gas, the gas supply source6may be a Nitrogen gas generation apparatus that generates the Nitrogen gas by using air as material.

When the material nozzle212supplies the build materials M together with the purge gas as described above, the gas supply source6may supply the purge gas to the mix apparatus12to which the build materials M are supplied from the material supply source1. Specifically, the gas supply source6may be connected to the mix apparatus12through a supply pipe62that connects the gas supply source6and the mix apparatus12. As a result, the gas supply source6supplies the purge gas to the mix apparatus12through the supply pipe62. In this case, the build materials M from the material supply source1may be supplied (specifically, pressure-fed) to the material nozzle212through the supply pipe11by the purge gas supplied from the gas supply source6through the supply pipe62. Namely, the gas supply source6may be connected to the material nozzle212through the supply pipe62, the mix apparatus12and the supply pipe11. In this case, the material nozzle212supplies, from the supply outlet214, the build materials M together with the purge gas for pressure-feeding the build materials M.

The control apparatus7is configured to control an operation of the processing system SYSa. The control apparatus7may include an arithmetic apparatus and a storage apparatus. The arithmetic apparatus may include at least one of a CPU (Central Processing Unit) and a GPU (Graphic Processing Unit), for example. The storage apparatus may include a memory. The control apparatus7serves as an apparatus for controlling the operation of the processing system SYSa by means of the arithmetic apparatus executing a computer program. The computer program is a computer program that allows the arithmetic apparatus to execute (namely, to perform) a below described operation that should be executed by the control apparatus7. Namely, the computer program is a computer program that allows the control apparatus7to function so as to make the processing system SYSa execute the below described operation. The computer program executed by the arithmetic apparatus may be recorded in the storage apparatus (namely, a recording medium) of the control apparatus7, or may be recorded in any recording medium (for example, a hard disk or a semiconductor memory) that is built in the control apparatus7or that is attachable to the control apparatus7. Alternatively, the arithmetic apparatus may download the computer program that should be executed from an apparatus disposed at the outside of the control apparatus7through a network interface.

For example, the control apparatus7may control an emitting aspect of the processing light EL by the irradiation optical system211. The emitting aspect may include at least one of an intensity of the processing light EL and an emitting timing of the processing light EL, for example. When the processing light EL includes the plurality of pulse lights, the emitting aspect may include at least one of an ON time of the pulsed light, an emission cycle of the pulsed light and a ratio (what we call a duty ratio) of a length of the ON time of the pulsed light and the emission cycle of the pulsed light, for example. Moreover, the control apparatus7may control a moving aspect of the processing head21by the head driving system22. The control apparatus7may control a moving aspect of the stage31by the stage driving system32. The moving aspect may include at least one of a moving distance, a moving speed, a moving direction and a moving timing (a moving period), for example. Moreover, the control apparatus7may control a supply aspect of the build materials M by the material nozzle212. The supply aspect may include at least one of the supplied amount (especially, the supplied amount per unit time) and a supply timing (a supply period).

The control apparatus7may not be disposed in the processing system SYSa. For example, the control apparatus7may be disposed at the outside of the processing system SYSa as a server or the like. In this case, the control apparatus7may be connected to the processing system SYSa through a wired and/or wireless network (alternatively, a data bus and/or a communication line). A network using a serial-bus-type interface such as at least one of IEEE1394, RS-232x, RS-422, RS-423, RS-485 and USB may be used as the wired network. A network using a parallel-bus-type interface may be used as the wired network. A network using an interface that is compatible to Ethernet (a registered trademark) such as at least one of 10-BASE-T, 100BASE-TX or 1000BASE-T may be used as the wired network. A network using an electrical wave may be used as the wireless network. A network that is compatible to IEEE802.1x (for example, at least one of a wireless LAN and Bluetooth (registered trademark)) is one example of the network using the electrical wave. A network using an infrared ray may be used as the wireless network. A network using an optical communication may be used as the wireless network. In this case, the control apparatus7and the processing system SYSa may be configured to transmit and receive various information through the network. Moreover, the control apparatus7may be configured to transmit an information such as a command and a control parameter to the processing system SYSa through the network. The processing system SYSa may include a reception apparatus that is configured to receive the information such as the command and the control parameter from the control apparatus7through the network. The processing system SYSa may include a transmission apparatus that is configured to transmit the information such as the command and the control parameter to the control apparatus7through the network (namely, an output apparatus that is configured to output an information to the control apparatus7). Alternatively, a first control apparatus that is configured to perform a part of the arithmetic processing performed by the control apparatus7may be disposed in the processing system SYSa and a second control apparatus that is configured to perform another part of the arithmetic processing performed by the control apparatus7may be disposed at an outside of the processing system SYSa

Note that at least one of an optical disc such as a CD-ROM, a CD-R, a CD-RW, a flexible disc, a MO, a DVD-ROM, a DVD-RAM, a DVD-R, a DVD+R, a DVD-RW, a DVD+RW and a Blu-ray (registered trademark), a magnetic disc such as a magnetic tape, an optical-magnetic disc, a semiconductor memory such as a USB memory, and another medium that is configured to store the program may be used as the recording medium recording therein the computer program that should be executed by the control apparatus7may include. Moreover, the recording medium may include a device that is configured to record the computer program (for example, a device for a universal use or a device for an exclusive use in which the computer program is embedded to be executable in a form of at least one of a software, a firmware and the like). Moreover, various arithmetic processing or functions included in the computer program may be realized by a logical processing block that is realized in the control apparatus7by means of the control apparatus7(namely, a computer) executing the computer program, may be realized by a hardware such as a predetermined gate array (a FPGA, an ASIC) of the control apparatus7, or may be realized in a form in which the logical process block and a partial hardware module that realizes an partial element of the hardware are combined.

(1-2) Operation of Processing System SYSa

Next, an operation of the processing system SYSa will be described. In the first example embodiment, the processing system SYSa performs an additive processing operation for forming the three-dimensional structural object ST on the workpiece W. Furthermore, the processing system SYSa performs, before performing the additive processing operation (alternatively, while performing the additive processing operation or after performing the additive processing operation), a coordinate matching operation for associating a processing coordinate system that is used when the head driving system22moves the processing head21with a stage coordinate system that is used when the stage driving system32moves the stage31. Furthermore, the processing system SYSa performs, before performing the additive processing operation (alternatively, while performing the additive processing operation or after performing the additive processing operation), an eccentric amount obtaining operation for obtaining an amount of a misalignment (typically, an eccentric amount δ) between the rotational axis of the stage31(namely, the rotational axis of the stage driving system32that serves as the rotation apparatus) and an ideal rotational axis of the workpiece W supported by the stage31. Thus, in the below described description, the additive processing operation, the coordinate matching operation and the eccentric amount obtaining operation will be described in sequence.

(1-2-1) Additive Processing Operation

Firstly, the additive processing operation will be described. As described above, the processing system SYSa forms the three-dimensional structural object ST by the Laser Metal Deposition. Thus, the processing system SYSa may form the three-dimensional structural object ST by performing an existing additive processing operation (a build operation in this case) based on the Laser Metal Deposition. Next, one example of the additive processing operation of forming the three-dimensional structural object ST by using the Laser Metal Deposition will be briefly described.

The processing system SYSa forms the three-dimensional structural object ST on the workpiece W based on a three-dimensional model data or the like (for example, a CAD (Computer Aided Design) data) of the three-dimensional structural object ST that should be formed. A measured data of the solid object measured by at least one of a non-illustrated measurement apparatus disposed in the processing system SYSa and a three-dimensional shape measurement device disposed separately from the processing system SYS may be used as the three-dimensional model data. The processing system SYSa sequentially forms a plurality of layered partial structural objects (it is referred to as the “structural layer” in the below described description) SL that are arranged along the Z axis direction in order to form the three-dimensional structural object ST, for example. For example, the processing system SYSa forms, one by one, the plurality of structural layers SL that are obtained by slicing the three-dimensional structural object ST along the Z axis direction. As a result, the three-dimensional structural object ST that is a layered structural body in which the plurality of structural layers SL are layered is formed. Next, a flow of an operation for forming the three-dimensional structural object ST by forming the plurality of structural layers SL one by one in sequence will be described.

Firstly, with reference toFIG.4AtoFIG.4E, an operation for forming each structural layer SL will be described. The processing system SYSa moves at least one of the processing head21and the stage31so that the target irradiation area EA is set at a desired area on a build surface MS that corresponds to a surface of the workpiece W or a surface of the formed structural layer SL, under the control of the control apparatus7. The processing system SYSa uses results of the coordinate matching operation and the eccentric amount obtaining operation in moving at least one of the processing head21and the stage31. Namely, the processing system SYSa moves at least one of the processing head21and the stage31based on the results of the coordinate matching operation and the eccentric amount obtaining operation so that the target irradiation area EA is set at the desired area on the build surface MS. Then, the processing system SYSa emits the processing light EL from the irradiation optical system211to the target irradiation area EA. In this case, a light concentration position (namely, a condensed position) of the processing light EL may be located on the build surface MS. As a result, as illustrated inFIG.4A, the melt pool (namely, a pool of a metal molten by the processing light EL) MP is formed on the build surface MS that is irradiated with the processing light EL. Moreover, the processing system SYSa supplies the build materials M from the material nozzle212under the control of the control apparatus7. Here, since the target irradiation area EA is coincident with the target supply area MA to which the build materials M are supplied as described above, the target supply area MA includes at least a part of an area at which the melt pool MP is formed. Thus, the processing system SYSa supplies the build materials M to the melt pool MP from the material nozzle212, as illustrated inFIG.4B. As a result, the build materials M supplied to the melt pool MP are molten. Then, when the melt pool MP is not irradiated with the processing light EL due to the movement of the processing head21, the build materials M molten in the melt pool MP are cooled and solidified (namely, coagulated). As a result, as illustrated inFIG.4C, the solidified build materials M are deposited on the build surface MS. Namely, a build object is formed by a deposition of the solidified build materials M.

The processing system SYSa repeats a series of build process including the formation of the melt pool MP by the irradiation of the processing light EL, the supply of the build materials M to the melt pool MP, the melting of the supplied build materials M and the solidification of the molten build materials M while changing the relative positional relationship between the processing head21and the workpiece W (namely, a relative positional relationship between the processing head21and the build surface MS), as illustrated inFIG.4D. In an example illustrated inFIG.4D, a series of build process is repeated while rotating the cylindrical workpiece W having a longitudinal direction along the X axis direction around the rotational axis along the X axis direction. In this case, the processing system SYSa irradiates an area on the build surface MS on which the build object should be formed with the processing light EL and does not irradiate an area on the build surface MS on which the build object should not be formed with the processing light EL. Namely, the processing system SYSa moves the target irradiation area EA along a predetermined moving trajectory on the build surface MS and irradiates the build surface MS with the processing light EL at a timing based on an aspect of a distribution of the area on which the build object should be formed. As a result, the melt pool MP also moves on the build surface MS along a moving trajectory based on the moving trajectory of the target irradiation area EA. Specifically, the melt pool MP is formed in series at a part that is irradiated with the processing light EL in the area along the moving trajectory of the target irradiation area EA on the build surface MS. Moreover, since the target irradiation area EA is coincident with the target supply area MA as described above, the target supply area MA also moves on the build surface MS along a moving trajectory based on the moving trajectory of the target irradiation area EA. As a result, as illustrated inFIG.4E, the structural layer SL that is an aggregation of the build object of the build materials M, which are solidified after being molten, is formed on the build surface MS. Namely, the structural layer SL that is an aggregation of the build object formed in a pattern based on the moving trajectory of the melt pool MP on the build surface MS (namely, the structural layer SL having a shape based on the moving trajectory of the melt pool MP in a planar view) is formed. Incidentally, when the target irradiation area EA is set at the area on which the build object should not be formed, the processing system SYSa may irradiate the target irradiation area EA with the processing light EL and stop the supply of the build materials M. Moreover, when the target irradiation area EA is set at the area on which the build object should not be formed, the processing system SYSa may supply the build materials M to the target irradiation area EA and irradiate the target irradiation area EA with the processing light EL having an intensity by which the melt pool MP is not formed.

The processing system SYSa repeats the operation for forming the structural layer SL based on the three-dimensional model data under the control of the control apparatus7. Specifically, the control apparatus7firstly generates slice data by performing a slicing process on the three-dimensional model data by a layer pitch. Note that data obtained by modifying a part of the slice data based on a characteristic of the processing system SYSa may be used. The processing system SYSa performs an operation for forming a first structural layer SL #1 on the build surface MS that corresponds to the surface of the workpiece W based on the three-dimensional model data corresponding to the structural layer SL #1 (namely, the slice data corresponding to the structural layer SL #1). As a result, as illustrated inFIG.5A, the structural layer SL #1 is formed on the build surface MS. Then, the processing system SYSa sets the surface (namely, an upper surface) of the structural layer SL #1 to be a new build surface MS and forms a second structural layer SL #2 on the new build surface MS. In order to form the structural layer SL #2, firstly, the control apparatus7moves at least one of the processing head21and the stage31so that the target irradiation area EA and the target supply area MA are set on the surface of the structural layer SL #1 (namely, the new build surface MS). By this, the light concentration position of the processing light EL is on the new build surface MS. Then, the processing system SYSa performs an operation for forming the structural layer SL #2 on the structural layer SL #1 based on the slice data corresponding to the structural layer SL #2, as with the operation for forming the structural layer SL #1 under the control of the control apparatus7. As a result, as illustrated inFIG.5B, the structural layer SL #2 is formed. Then, the same operation is repeated until all structural layers SL constituting the three-dimensional structural object ST that should be formed on the workpiece W are formed. As a result, the three-dimensional structural object ST is formed by a layered structural object in which the plurality of structural layers SL are layered, as illustrated inFIG.5C.

(1-2-2) Coordinate Matching Operation

Next, with reference toFIG.6, the coordinate matching operation will be described.FIG.6is a flowchart that illustrates a flow of the coordinate matching operation.

As illustrated inFIG.6, firstly, a calibration plate34is placed on the stage31(a step S11). Especially, the calibration plate34is placed on the stage31so that a positional relationship between the calibration plate34and the stage31is a desired positional relationship. In the first example embodiment, in order to place the calibration plate34on the stage31so that the positional relationship between the calibration plate34and the stage31is the desired positional relationship, a mark for an alignment is formed on each of the calibration plate34and the stage31. Next, with reference toFIG.7toFIG.11, examples of the stage31and the calibration plate34on which the marks for the alignment are formed will be described.FIG.7is a planar view that illustrates the stage31on which the mark for a position adjustment is formed.FIG.8is a VII-VII′ cross-sectional view of the stage31illustrated inFIG.7.FIG.9is a planar view that illustrates the calibration plate34on which the mark for the alignment is formed.FIG.10is a IX-IX′ cross-sectional view of the calibration plate34illustrated inFIG.9.FIG.11is a planar view that illustrates the calibration plate34that is placed on the stage31.

As illustrated inFIG.7andFIG.8, a plurality of pins319are formed on the stage31as the marks for the alignment. In an example illustrated inFIG.7andFIG.8, two pins319are formed on an upper surface (especially, an upper surface that is higher than or at the same height as an upper surface of the stage31θZ) of the stage31θX included in the stage31. However, a formed position and the number of the pin319are not limited to examples illustrated inFIG.7andFIG.8. The pin319is a member that protrudes from the upper surface of the stage31(the upper surface of the stage31θX in the example illustrated inFIG.7andFIG.8) along the Z axis direction. Note that an information related to positions of the pins319in the stage coordinate system is an information that is already known to the control apparatus7.

As illustrated inFIG.9andFIG.10, the calibration plate34includes a base member341. The base member341is a plate-shaped member. The base member341has a shape and a size that allow it to be placed on the stage31. A plurality of through-holes342are formed in the base member341as the marks for the alignment. In an example illustrated inFIGS.9and10, two through-holes342are formed in the base member341. The through-hole342penetrates the base member341along the Z axis direction.

In the first example embodiment, as illustrated inFIG.11, the calibration plate34is placed on the stage31so that the pins319are inserted into the through-holes342. The calibration plate34is placed on the stage31(namely, on the stage31θX and the stage31θZ) in a state where the pins319are inserted into the through-holes322. The stage31supports (for example, holds) the calibration plate34in a state where the pins319are inserted into the through-holes322. Thus, an arrangement aspect of the through-holes342is same as an arrangement aspect of the pins319. Furthermore, the number of the through-holes342is equal to (alternatively, may be more than) the number of the pins319. As a result, the calibration plate34is placed on the stage31to have the desired positional relationship relative to the stage31. Specifically, the calibration plate34is placed on the stage31to have the desired positional relationship relative to the pins319on the stage31. The position at which the pin319is formed may be used as a fiducial position on the stage31in placing the calibration plate34on the stage31. In this case, the calibration plate34is placed on the stage31in a state where it is aligned to have the desired positional relationship relative to the fiducial position on the stage31.

A calibration pattern CP, which is measurable by the measurement apparatus4, is formed on the calibration plate34. In the example illustrated inFIG.9, the calibration pattern CP is a measurement pattern including a plurality of calibration markers CM arranged in a matrix pattern. A position at which the calibration pattern CP is formed (in the example illustrated inFIG.9, positions at which the plurality of calibration markers CM are formed) on the calibration plate34is an information that is already known to the control apparatus7. In this case, since the calibration plate34is placed on the stage31to have the desired positional relationship relative to the pins319placed at known positions in the stage coordinate system, the position at which the calibration pattern CP is formed in the stage coordinate system is also an information that is already known to the control apparatus7.

A thermosensitive film343having a thermal sensitivity (namely, sensitivity) to the processing light EL is formed on the calibration plate34. Note that a photosensitive film having a photosensitivity (namely, sensitivity) to the processing light EL may be formed on the calibration plate34, in addition to or instead of the thermosensitive film343. The thermosensitive film343is formed on the calibration plate34to cover the calibration pattern CP. The thermosensitive film343is transparent to the measurement light ML (for example, a visible light) that is used by the measurement apparatus4. Thus, the calibration pattern CP covered with the thermosensitive film343is measurable by the measurement apparatus4.

Again inFIG.6, after the calibration plate34is placed on the stage31, the control apparatus7irradiates the processing unit2and the stage unit3to irradiate at least a part of the calibration plate34with the processing light EL (a step S12). Specifically, the control apparatus7changes the relative positional relationship between the processing head21and the stage31so that the target irradiation area EA moves along a predetermined moving pattern on at least a part of the thermosensitive film343of the calibration plate34. Specifically, the control apparatus7moves the processing head21so that the target irradiation area EA moves along a predetermined moving trajectory on at least a part of the thermosensitive film343of the calibration plate34. In this case, the control apparatus7may not move the stage31. Furthermore, the control apparatus7irradiates the target irradiation area EA, which moves along the predetermined moving trajectory on at least a part of the thermosensitive film343, with the processing light EL. As a result, as illustrated inFIG.12that is a planar view illustrating the calibration plate34that is irradiated with the processing light EL, an exposed pattern PP corresponding to the moving trajectory of the target irradiation area EA is formed on at least a part of the thermosensitive film343. In an example illustrated inFIG.12,5the target irradiation area EA moves along a grid-like moving trajectory including a moving trajectory extending along each of the X axis direction and the Y axis direction between the plurality of calibration markers CM.

Then, the measurement apparatus4measures at least a part of the calibration plate34(a step S13). Specifically, the measurement apparatus4measures the exposed pattern PP formed on the thermosensitive film343of the calibration plate34. Namely, the measurement apparatus4measures a part of the thermosensitive film343that is exposed by the processing light EL. Moreover, since the thermosensitive film343is transparent to the measurement light ML, the measurement apparatus4measures the calibration pattern CP as well as the exposed pattern PP. Therefore, a measured result by the measurement apparatus4at the step S13includes an information related to a measured result of the exposed pattern PP and an information related to a measured result of the calibration pattern CP.

Then, the control apparatus7associates the processing coordinate system with the stage coordinate system based on the measured result by the measurement apparatus4at the step S13(a step S14). Specifically, the control apparatus7calculates a position of the exposed pattern PP and a position of the calibration pattern CP based on the measured result by the measurement apparatus4. Here, as described above, the calibration plate34on which the calibration pattern CP is formed has the desired positional relationship relative to the stage θZ of the stage31and the position at which the calibration pattern CP is formed is the information that is already known to the control apparatus7. Thus, the calculated position of the calibration pattern CP substantially corresponds to the position of the calibration pattern CP in the stage coordinate system. Thus, the control apparatus7is capable of calculating the position of the exposed pattern PP in the stage coordinate system by comparing the position of the calibration pattern CP in the stage coordinate system with the position of the exposed pattern PP. Furthermore, since the exposed pattern PP is formed by the processing light EL from the processing head21, the position of the exposed pattern PP indirectly indicates a position of the processing head21. Namely, the position of the exposed pattern PP indirectly indicates the position of the processing head21in the processing coordinate system. Thus, the control apparatus7is capable of associating the position of the processing head21in the processing coordinate system with the position of the calibration pattern CP in the stage coordinate system based on the position of the exposed pattern PP and the position of the calibration pattern CP. As a result, the control apparatus7is capable of associating the processing coordinate system with the stage coordinate system. Note that the position of the exposed pattern PP and the position of the calibration pattern CP may be measured by a measurement apparatus (as one example, an external measurement apparatus) that is different from the measurement apparatus4.

After the processing coordinate system is associated with the stage coordinate system, a misalignment of the processing coordinate system relative to the stage coordinate system is calculatable. The misalignment of the processing coordinate system relative to the stage coordinate system corresponds to a difference between an ideal (namely, a designed) position of the exposed pattern PP and the actually measured position of the exposed pattern PP. The misalignment of the processing coordinate system relative to the stage coordinate system may include a difference between an origin point of the stage coordinate system and an origin point of the processing coordinate system, for example. The misalignment of the processing coordinate system relative to the stage coordinate system may include an misalignment of a moving plane of the processing head21(for example, at least one of a moving plane when the processing head21moves along the X axis and a moving plane when the processing head21moves along the Y axis) relative to an axis of the stage coordinate system, for example. In this case, the control apparatus7may calculate a movement correction value that allows the processing head21to move so as to cancel (in other words, correct) the misalignment. For example, the control apparatus7may calculate at least one of a movement correction value for correcting the moving direction when the processing head21moves along the X axis, a movement correction value for correcting the moving distance when the processing head21moves along the X axis, a movement correction value for correcting the moving direction when the processing head21moves along the Y axis and a movement correction value for correcting the moving distance when the processing head21moves along the Y axis. When the above described additive processing operation is performed, the control apparatus7may move the processing head21by using the movement correction value calculated by the coordinate matching operation. Namely, When the above described additive processing operation is performed, the control apparatus7may move the processing head21based on the measured result of the calibration plate34in the coordinate matching operation. As a result, even when there is the misalignment of the processing coordinate system relative to the stage coordinate system, the control apparatus7is capable of moving the processing head in a same manner as a case where there is no misalignment of the processing coordinate system relative to the stage coordinate system. Namely, as a result, even when there is the misalignment of the processing coordinate system relative to the stage coordinate system, the control apparatus7is capable of moving the processing head21so that the desired position on the workpiece W is irradiated with the processing light EL.

Moreover, after the processing coordinate system is associated with the stage coordinate system, the control apparatus7is capable of converting a certain coordinate position in either one of the e processing coordinate system and the stage coordinate system into a coordinate position in the other one of the e processing coordinate system and the stage coordinate system. Thus, the operation for “associating the e processing coordinate system with the stage coordinate system” may be regarded to be substantially equivalent to an operation for calculating an information (for example, a conversion matrix) that is used to convert a certain coordinate position in either one of the e processing coordinate system and the stage coordinate system into a coordinate position in the other one of the e processing coordinate system and the stage coordinate system

Note that the calibration plate34is attached to the stage31θX in the above described example, however, the calibration plate34may be attached to the stage31θZ.

(1-2-3) Eccentric Amount Obtaining Operation

Next, the eccentric amount obtaining operation will be described. In the below described description, a technical reason why the eccentric amount obtaining operation is performed will be described firstly, and then, a flow of the eccentric amount obtaining operation will be described.

Firstly,FIG.13illustrates the workpiece W that is supported by the stage31so that the eccentric amount δ that is the amount of the misalignment between the rotational axis of the stage31and the ideal rotational axis of the workpiece W is zero. Note thatFIG.13toFIG.17omit an illustration of a holding clasp for fixing the workpiece W on the stage31for the purpose of simple illustration. In the first example embodiment, since the stage31θZ supports the workpiece W, it is assumed that the eccentric amount δ means the amount of the misalignment between the rotational axis of the stage31θZ (in the below described description, it is referred to as a “rotational axis φZ”) and the ideal rotational axis of the workpiece W (in the below described description, it is referred to as a “rotational axis φW”). Note that the rotational axis φW may be typically an axis passing through a centroid (namely, a center of mass) of the workpiece W. In an example illustrated inFIG.13, the rotational axis φW of the cylindrical workpiece W extending in a direction along the rotational axis φZ is an axis passing through a center of a cylinder. In this case, the eccentric amount δ may mean an amount of an misalignment between the rotational axis φZ and the centroid of the workpiece W.

In a case where the eccentric amount δ is zero as illustrated inFIG.13, the relative positional relationship between the processing head21and the workpiece W does not change in a state where the processing head21does not move when the stage31θZ rotates around the rotational axis φZ. Specifically,FIG.14Aillustrates the relative positional relationship between the processing head21and the workpiece W supported by the stage31θZ rotating around the rotational axis φZ parallel to the Z axis in a state where the eccentric amount δ is zero.FIG.14Billustrates the relative positional relationship between the processing head21and the workpiece W supported by the stage31θZ rotating around the rotational axis φZ inclined with respect to the Z axis in a state where the eccentric amount δ is zero.FIG.14Billustrates the relative positional relationship between the processing head21and the workpiece W supported by the stage31θZ rotating around the rotational axis φZ inclined perpendicular to the Z axis in a state where the eccentric amount δ is zero. Note that a state of the rotational axis φZ relative to the Z axis is changeable by the rotation of the stage31θX. As illustrated inFIG.14AtoFIG.14C, when the eccentric amount δ is zero, the rotational axis φZ overlaps with (namely, is same as) the rotational axis φW. Thus, when the stage31θZ rotates around the rotational axis φZ, the workpiece W rotates around the rotational axis φW. As a result, the relative positional relationship between the processing head21and the workpiece W does not change.

On the other hand,FIG.15illustrates the workpiece W that is supported by the stage31so that the eccentric amount δ is not zero. In a case where the eccentric amount δ is not zero, there is a possibility that the relative positional relationship between the processing head21and the workpiece W changes even in a state where the processing head21does not move when the stage31θZ rotates around the rotational axis φZ. Namely, there is a possibility that a relative positional relationship between the processing coordinate system and the workpiece W changes.

Specifically, each ofFIG.16AandFIG.16Billustrate the relative positional relationship between the processing head21and the workpiece W supported by the stage31θZ rotating around the rotational axis φZ parallel to the Z axis in a state where the eccentric amount δ is not zero. As illustrated inFIG.16AandFIG.16B, when the eccentric amount δ is not zero, the rotational axis φZ does not overlap with (namely, is not same as) the rotational axis φW. Thus, when the stage31θZ rotates around the rotational axis φZ, the workpiece W rotates around the rotational axis φZ that is different from the rotational axis φW. As a result, the workpiece W is displaced relative to the processing head21(relative to the processing coordinate system) toward a direction based on a rotational angle of the stage31θZ around the rotational axis φZ by a displaced amount based on the rotational angle of the stage31θZ around the rotational axis φZ. Specifically, the workpiece W is displaced relative to the processing head21(relative to the processing coordinate system) in a plane perpendicular to the rotational axis φZ (in an example illustrated inFIG.16AandFIG.16B, the XY plane).

Each ofFIG.17AandFIG.17Billustrate the relative positional relationship between the processing head21and the workpiece W supported by the stage31θZ rotating around the rotational axis φZ inclined with respect to the Z axis in a state where the eccentric amount δ is not zero. Even in this case, the workpiece W is displaced relative to the processing head21(relative to the processing coordinate system) in a plan perpendicular to the rotational axis φZ (in the example illustrated inFIG.17AandFIG.17B, a plane that intersects with the X axis, the Y axis and the Z axis).

Each ofFIG.18AandFIG.18Billustrate the relative positional relationship between the processing head21and the workpiece W supported by the stage31θZ rotating around the rotational axis φZ perpendicular to the Z axis in a state where the eccentric amount δ is not zero. Even in this case, the workpiece W is displaced relative to the processing head21(relative to the processing coordinate system) in a plan perpendicular to the rotational axis φZ (in the example illustrated inFIG.18AandFIG.18B, the XZ plane).

There is a possibility that the displacement of the workpiece W relative to the processing head21due to the rotation of the stage31θZ (namely, a variation of the relative positional relationship between the processing head21and the workpiece W) results in an undesired variation of the irradiation position of the processing light EL on the workpiece W. As a result, there is a possibility that the processing head21is not capable of irradiating the desired position on the workpiece W with the processing light EL. Thus, in the first example embodiment, the processing system SYSa obtains the eccentric amount δ by the eccentric amount obtaining operation and processes the workpiece W by using the obtained eccentric amount δ in performing the additive processing operation (namely, during the processing of the workpiece W, during the irradiation of the processing light EL). Specifically, the processing system SYSa rotates the stage31(for example, at least one of the stage31θX and the stage310Z) and moves the processing head21based on the obtained eccentric amount S. Namely, the processing system SYSa moves the processing head21in parallel with the rotation of the stage31based on the obtained eccentric amount S.

More specifically, the processing system SYSa rotates the stage31based on the eccentric amount δ and moves the processing head21based on the eccentric amount δ so as to reduce (typically, cancel, the same is applied to the below described description) an influence of the displacement of the workpiece W relative to the processing head21due to the rotation of the stage31. Here, as described above, the workpiece W is displaced relative to the processing head21(relative to the processing coordinate system) in the plane perpendicular to the rotational axis φZ due to the rotation of the stage31. Thus, the processing system SYSa may move the processing head21in the plane perpendicular to the rotational axis φZ based on the eccentric amount δ so that the desired position on the workpiece W is irradiated with the processing light EL even when the workpiece W is displaced relative to the processing head21due to the rotation of the stage31. For example, when the workpiece W is displaced relative to the processing head21(relative to the processing coordinate system) in the XY plane as illustrated inFIG.16AandFIG.16B, the processing system SYSa may move the processing head21in the XY plane so that the desired position on the workpiece W is irradiated with the processing light EL even when the workpiece W is displaced relative to the processing head21due to the rotation of the stage31. In this case, the processing system SYSa may move the processing head21along at least one of the X axis direction and the Y axis direction. For example, when the workpiece W is displaced relative to the processing head21(relative to the processing coordinate system) in the plane that intersects with the X axis, the Y axis and the Z axis (namely, a plane that is inclined with respect to the moving direction of the processing head21) as illustrated inFIG.17AandFIG.17B, the processing system SYSa may move the processing head21in the plane that intersects with the X axis, the Y axis and the Z axis so that the desired position on the workpiece W is irradiated with the processing light EL even when the workpiece W is displaced relative to the processing head21due to the rotation of the stage31. In this case, the processing system SYSa may move (namely, move up and down) the processing head21along the Z axis direction and may move the processing head21along at least one of the X axis direction and the Y axis direction. For example, when the workpiece W is displaced relative to the processing head21(relative to the processing coordinate system) in the XZ plane as illustrated inFIG.18AandFIG.18B, the processing system SYSa may move the processing head21in the XZ plane so that the desired position on the workpiece W is irradiated with the processing light EL even when the workpiece W is displaced relative to the processing head21due to the rotation of the stage31. In this case, the processing system SYSa may move (namely, may move up and down) the processing head21along the Z axis direction.

The processing system SYSa is capable of irradiating the desired position on the workpiece W with the processing light EL by moving the processing head21even when the workpiece W is displaced relative to the processing head21(relative to the processing coordinate system) due to the rotation of the stage31θZ. As a result, the processing system SYSa is capable of irradiating the desired position on the workpiece W with the processing light EL without performing an strict alignment of the workpiece W on the rotating stage31.

The processing system SYSa may use a measured result by the position measurement device33that measures the position of the stage31. For example, the processing system SYSa may calculate the rotational angle of the stage31θZ around the rotational axis φZ based on the measured result by the position measurement device33and may move the processing head21based on the calculated rotational angle.

Incidentally, when the stage31is movable along at least one of the X axis, the Y axis and the Z axis, the processing system SYSa may move the stage31in addition to or instead of the processing head21so that the desired position on the workpiece W is irradiated with the processing light EL even when the workpiece W is displaced relative to the processing head21due to the rotation of the stage31. Namely, the processing system SYSa may move the workpiece W in addition to or instead of the processing head21by considering the displacement of the workpiece W relative to the processing head21due to the rotation of the stage31.

Moreover, when the irradiation optical system211includes an irradiation position change optical member that is movable to change the irradiation position of the processing light EL on the workpiece W, the processing system SYSa may move the irradiation position change optical member in addition to or instead of the processing head21by considering the displacement of the workpiece W relative to the processing head21due to the rotation of the stage31. As one example of the irradiation position change optical member, there is a Galvano mirror2111as illustrated inFIG.19that illustrates a configuration of the irradiation optical system211. In this case, the processing system SYSa may move the Galvano mirror2111(specifically, may control the movement of the Galvano mirror2111) by considering the displacement of the workpiece W relative to the processing head21due to the rotation of the stage31. As another example of the irradiation position change optical member, there is a polygonal mirror.

Next, with reference toFIG.20, the eccentric amount obtaining operation will be described.FIG.20is a flowchart that illustrates the flow of the eccentric amount obtaining operation.

As illustrated inFIG.20, the control apparatus7calculates the rotational axis of the stage31(the rotational axis φZ of the stage31θZ in the first example embodiment) by using the measured result of the stage31by the measurement apparatus4(a step S21). Note that a detailed description of an operation for calculating the rotational axis φZ will be described later in detail with reference toFIG.21. Furthermore, the control apparatus7calculates the rotational axis φW of the workpiece W by using the measured result of the workpiece W by the measurement apparatus4before or after the step S21(a step S22). Note that a detailed description of an operation for calculating the rotational axis φW will be described later in detail with reference toFIG.22. Then, the control apparatus7calculates the eccentric amount δ based on the rotational axis φZ calculated at the step S21and the rotational axis φW calculated at the step S22(a step S23).

Note that the rotational axis φZ calculated at the step S21is an information unique to the position of the stage31. Thus, it can be said that the rotational axis φZ calculated at the step S21is one specific example of a stage position information related to the position of the stage31. In this case, the control apparatus7may calculate any stage position information related to the position of the stage31in addition to or instead of the rotational axis φZ by using the measured result of the stage31by the measurement apparatus4. Then, the control apparatus7may calculate the eccentric amount δ based on the stage position information.

Incidentally, when the position of the rotational axis φZ or the position of the stage31is already known, the step S21may not be performed.

The rotational axis φW calculated at the step S22is an information unique to the position of the workpiece W. Thus, it can be said that the rotational axis φW calculated at the step S2wis one specific example of a workpiece position information related to the position of the workpiece W. In this case, the control apparatus7may calculate any workpiece position information related to the position of the workpiece W in addition to or instead of the rotational axis φW by using the measured result of the workpiece W by the measurement apparatus4. Then, the control apparatus7may calculate the eccentric amount δ based on the workpiece position information.

It can be said that the eccentric amount δ calculated at the step S23is one specific example of a positional relationship information related to the positional relationship between the rotational axis φZ of the stage31θZ and the workpiece W. Namely, it can be said that the eccentric amount δ calculated at the step S23is one specific example of the positional relationship information related to the positional relationship between the stage31and the workpiece W. In this case, the control apparatus7may calculate any positional relationship information related to the positional relationship between the rotational axis φZ of the stage310Z and the workpiece W in addition to or instead of the eccentric amount S. Then, in the additive processing operation, the processing system SYSa may move the processing head21based on any positional relationship information by considering the displacement of the workpiece W relative to the processing head21due to the rotation of the stage31.

Next, with reference toFIG.21, the operation for calculating the rotational axis φZ of the stage31θZ at the step S21inFIG.20will be described.FIG.21is a flowchart that illustrates the flow of the operation for calculating the rotational axis φZ of the stage31θZ at the step S21inFIG.20.

As described above, the control apparatus7calculates the rotational axis φZ of the stage31θZ by using the measured result of the stage31by the measurement apparatus4. However, in the first example embodiment, the measurement apparatus4measures at least a part of the calibration plate34placed on the stage31instead of directly measuring at least a part of the stage31in order to easily calculating the rotational axis φZ from the measured result by the measurement apparatus4. Namely, the measurement apparatus4indirectly measures at least a part of the stage31by measuring at least a part of the calibration plate34placed on the stage31. However, the measurement apparatus4may directly measure at least a part of the stage31. For example, when the calibration pattern CP is formed on the stage31as described later, the measurement apparatus4may directly measure at least a part of the stage31(for example, a part on which the calibration pattern CP is formed).

Thus, as illustrated inFIG.21, the calibration plate34is placed on the stage31θZ of the stage31(a step S210). Even in the eccentric amount obtaining operation, the calibration plate34may be placed on the stage31so that the positional relationship between the calibration plate34and the stage31θZ of the stage31is the desired positional relationship, as with the coordinate matching operation. However, the thermosensitive film343may not be formed on the calibration plate34placed on the stage31in the eccentric amount obtaining operation. Note that another calibration plate on which a desired calibration pattern CP is formed may be placed on the stage31instead of the calibration plate34.

Then, the control apparatus7controls the stage driving system32so that the stage31is located at an origin point position (a step S211). The origin point position may be a position at which the rotational angle measured by the position measurement device33is zero.

Then, the measurement apparatus4measures at least a part of the calibration plate34(a step S212). Specifically, the measurement apparatus4measures the calibration pattern CP formed on the calibration plate34.

Then, the control apparatus7determines whether or not the measurement of the calibration plate34should be ended (a step S213). For example, the control apparatus7may determine that the measurement of the calibration plate34should be ended when the measurement apparatus4measures the calibration plate34by a first desired number of times. It is preferable that the first desired number of times be at least two times.

As a result of the determination at the step S213, when it is determined that the measurement of the calibration plate34should not be ended (the step S213: No), the control apparatus7rotates the stage31θZ around the rotational axis φZ by a first desired angle (step S214). The first desired angle may be any angle smaller than 360 degree. The first desired angle may be any angle that is different from a multiple of 360 degree. Then, the measurement apparatus4measures the calibration plate34again (the step S212). Namely, in the first example embodiment, the measurement apparatus4measures the calibration plate34each time the stage31rotates. The measurement apparatus4measures the calibration plate34a plurality of times from different directions. The measurement apparatus4measures the calibration plate34in different attitudes a plurality of times.

On the other hand, as a result of the determination at the step S213, when it is determined that the measurement of the calibration plate34should be ended (the step S213: Yes), the control apparatus7calculates the rotational axis φZ of the stage31θZ by using the measured result of the calibration plate34by the measurement apparatus4at the step S212(a step S215). Specifically, the control apparatus7is capable of calculating the position of the calibration pattern CP based on the measured result of the calibration plate34. The position of the calibration pattern CP substantially corresponds to the position of the stage31supporting the calibration plate34. Therefore, the control apparatus7may be regarded to indirectly calculate the position of the stage31by calculating the position of the calibration pattern CP. The measurement apparatus4may be regarded to indirectly measure the position of the stage31by measuring the position of the calibration pattern CP. The control apparatus7calculates the position of the calibration pattern CP as many times as the stage31θZ rotates. Namely, the control apparatus7calculates the position of the calibration pattern CP for each rotating angle of the stage31θZ during the measurement of the calibration plate34. Then, the control apparatus7performs a fitting of the position of the calibration pattern CP calculated for each rotating angle of the stage31θZ by a circle. Then, the control apparatus7calculates, as the rotational axis φZ of the stage31θZ, an axis that passes through a center of the circle obtained by the fitting and that is perpendicular to the circle.

Note that the control apparatus7may calculates the rotational axis of the stage31θX by performing an operation that is same as the operation illustrated inFIG.21.

Next, with reference toFIG.22, the operation for calculating the rotational axis φW of the workpiece W at the step S22inFIG.20will be described.FIG.22is a flowchart that illustrates the flow of the operation for calculating the rotational axis φW of the workpiece W at the step S22inFIG.20.

As illustrated inFIG.22, firstly, the workpiece W is placed on the stage (a step S221). Then, the measurement apparatus4measures at least a part of the workpiece W (a step S222).

Then, the control apparatus7determines whether or not the measurement of the workpiece W should be ended (a step S223). For example, the control apparatus7may determine that the measurement of the workpiece W should be ended when the measurement apparatus4measures the workpiece W by a second desired number of times. It is preferable that the second desired number of times be at least two times.

As a result of the determination at the step S223, when it is determined that the measurement of the workpiece W should not be ended (the step S223: No), the control apparatus7rotates the stage31θZ around the rotational axis φZ by a second desired angle (step S224). The second desired angle may be any angle smaller than 360 degree. The second desired angle may be any angle that is different from a multiple of 360 degree. Then, the measurement apparatus4measures the workpiece W again (the step S211). Namely, in the first example embodiment, the measurement apparatus4measures the workpiece W each time the stage31rotates. The measurement apparatus4measures the workpiece W a plurality of times from different directions. The measurement apparatus4measures the workpiece W in different rotational attitudes a plurality of times.

On the other hand, as a result of the determination at the step S223, when it is determined that the measurement of the workpiece W should be ended (the step S223: Yes), the control apparatus7calculates the rotational axis φW of the workpiece W by using the measured result of the workpiece W by the measurement apparatus4at the step S222(a step S225). Specifically, the control apparatus7generates an information related to a position and/or a shape of a part of the workpiece W in a certain rotational attitude included in a measurement range of the measurement apparatus4based on the measured result of the workpiece W in a certain rotational attitude. As one example, the control apparatus7may generate a point cloud information related to a plurality of points constituting a part of the surface of the workpiece W in a certain rotational attitude included in the measurement range of the measurement apparatus4based on the measured result of the workpiece W in a certain rotational attitude. The control apparatus7repeats an operation for generating the information related to the position and/or the shape of at least a part of the workpiece W as many times as the workpiece W is measured. Then, the information related to the position and/or the shape of at least a part of the workpiece W is merged based on the rotational attitude of the workpiece W. For example, the control apparatus7may generate a first point cloud information from the measured result of the workpiece W in a first rotational attitude, generate a second point cloud information from the measured result of the workpiece W in a second rotational attitude, and merge the first and second point cloud information based on the first and second rotational attitudes. As a result, compared to a case where the measurement apparatus4measures the workpiece W from only one direction, an area a presence of which is indicated by the point cloud information is larger on the surface of the workpiece W. In other words, there is a higher possibility that the control apparatus7is capable of recognizing whole of the workpiece W. Incidentally, when it is found that there is a part of the workpiece W the presence of which is not indicated by the merged point cloud information, the control apparatus7may control the measurement apparatus4to newly measure this part, and may further merge the measured result by the measurement apparatus4with the merged point cloud information. Then, the control apparatus7calculates the rotational axis φW of the workpiece W based on the merged point cloud information. For example, when a three-dimensional model (for example, a design information) of the workpiece W can be obtained, the control apparatus7may perform a fitting of the three-dimensional model of the workpiece W on the merged point cloud information, and may calculate the rotational axis φW of the workpiece W based on the three-dimensional model on which the fitting is already performed. Alternatively, when the three-dimensional model of the workpiece W cannot be obtained, the control apparatus7may generate a surface model (alternatively, a solid model) of the workpiece W based on the merged point cloud information, and may calculate the rotational axis φW of the workpiece W based on the surface model (alternatively, the solid model).

To summarize the control apparatus7described above, the control apparatus7obtains a plurality of measured results obtained by measuring the calibration plate34a plurality of times from different directions, and calculates the rotational axis φZ of the stage31based on the plurality of measured results at the step S21inFIG.20. Furthermore, the control apparatus7obtains a plurality of measured results obtained by measuring the workpiece W a plurality of times from different directions, and calculates the rotational axis φW of the workpiece W based on the plurality of measured results at the step S22inFIG.20. Furthermore, the control apparatus7calculates the eccentric amount δ based on the calculated rotational axes φZ and φW. Thus, the control apparatus7may be regarded to serve as a measurement apparatus or an arithmetic apparatus that includes: a measurement part that is configured to obtain a first measured result of the workpiece W measured from a first direction (namely, the workpiece W in a first rotational attitude) and a second measured result of the workpiece W measured from a second direction (namely, the workpiece W in a second rotational attitude); and a relationship obtaining part that is configured to obtain the eccentric amount δ (namely, a relationship between the rotational axis φZ and the workpiece W) based on the first and second measured results. Moreover, the eccentric amount δ corresponds to a translational movement component, in which a rotational movement component is removed, of a movement component of one point of the workpiece W when the stage31θZ is rotated (namely, the workpiece W is rotated) in the eccentric amount obtaining operation. Thus, the control apparatus7may be regarded to serve as a measurement apparatus or an arithmetic apparatus that includes: the measurement part that is configured to obtain the first measured result of the workpiece W measured from the first direction (namely, the workpiece W in the first rotational attitude) and the second measured result of the workpiece W measured from the second direction (namely, the workpiece W in the second rotational attitude); and a difference obtaining part that is configured to obtain the translational movement component, in which the rotational movement component is removed, of the movement component of one point of the workpiece W when the stage31θZ is rotated (namely, the workpiece W is rotated) in the eccentric amount obtaining operation.

Note that the control apparatus7calculates the rotational axis ϕW of the workpiece W from the point cloud information here, however, the control apparatus7may calculate any information related to the position of the workpiece W from the point cloud information.

(1-3) Technical Effectiveness

As described above, the processing system SYSa in the first example embodiment is capable of rotating the stage31and moving the processing head21by considering the displacement of the workpiece W relative to the processing head21due to the rotation of the stage31based on the eccentric amount δ obtained from the measured result by the measurement apparatus4. Thus, even when the workpiece W is displaced relative to the processing head21due to the rotation of the stage31, the processing system SYSa is capable of irradiating the desired position on the workpiece W with the processing light EL. As a result, the processing system SYSa is capable of properly processing the workpiece W. As one example, the processing system SYSa is capable of processing the workpiece W with a small processing error.

(2) Processing System SYS in Second Example Embodiment

Next, the processing system SYS in a second example embodiment (in the below described description, the processing system SYS in the second example embodiment is referred to as a “processing system SYSb”) will be described. The processing system SYSb in the second example embodiment is different from the processing system SYSa in the first example embodiment in that it may perform a removal processing for removing a part of the workpiece W by irradiating the workpiece W with the processing light EL. For example, the processing system SYSb may perform the removal processing so that the shape of the workpiece W is a desired shape. For example, the processing system SYSb may perform the removal processing to form a desired structure on the workpiece W. For example, the processing system SYSb may perform the removal processing to form a desired structure on the surface of the workpiece W. For example, the processing system SYSb may perform the removal processing so that the surface of the workpiece W is polished.

When the removal processing is performed, the processing system SYSb may form a riblet structure on the workpiece W. The riblet structure may be a structure by which a resistance (especially, a frictional resistance, a turbulent frictional resistance) of the surface of the workpiece W to a fluid is reducible. The riblet structure may be a structure by which a noise generated when the fluid and the surface of the workpiece W relatively moves is reducible. The riblet structure include a structure in which a plurality of grooves each of which extends along a first direction (the Y axis direction) along the surface of the workpiece W are arranged along a second direction (the X axis direction) that is along the surface of the workpiece W and that intersects with the first direction, for example.

When the removal processing is performed, the processing system SYSb may form any structure having any shape on the surface of the workpiece W. A structure that generates a swirl relative to a flow of the fluid on the surface of the workpiece W is one example of any structure. A structure that add a hydrophobic property to the surface of the workpiece W is one example of any structure. A fine texture structure (typically, a concave and convex structure) that is formed regularly or irregularly in a micro/nano-meter order is another example of any structure. This fine texture structure may include at least one of a shark skin structure or a dimple structure that has a function of reducing a resistance from a fluid (a liquid and/or a gas). The fine texture structure may include a lotus leaf surface structure that has at least one of a liquid repellent function and a self-cleaning function (for example, has a lotus effect). The fine texture structure may include at least one of a fine protrusion structure that has a liquid transporting function (US2017/0044002A1), a concave and convex structure that has a lyophile effect, a concave and convex structure that has an antifouling effect, a moth eye structure that has at least one of a reflectance reduction function and a liquid repellent function, a concave and convex structure that intensifies only light of a specific wavelength by interference to have a structural color, a pillar array structure that has an adhesion function using van der Waals force, a concave and convex structure that has an aerodynamic noise reduction function, a honeycomb structure that has a droplet collection function and so on.

FIG.23andFIG.24illustrates the processing system SYSb.FIG.23is a block diagram that illustrates a system configuration of the processing system SYSb.FIG.24is a cross-sectional view that illustrates a configuration of the processing system SYSb. As illustrated inFIG.23andFIG.24, the processing system SYSb is different from the processing system SYSa in that it may not include the material supply source1and mix apparatus12. Furthermore, the processing system SYSb is different from the processing system SYSa in that it may not include the material nozzle212. Specifically, the processing system SYSb is different from the processing system SYSa in that it includes a processing unit2bincluding a processing head21bthat does not include the material nozzle212instead of the processing unit2including the processing head21that includes the material nozzle212. Namely, the processing system SYSb is different from the processing system SYSa in that it may not include a component for supplying the build materials M. Another feature of the processing system SYSb may be same as another feature of the processing system SYSa.

The above described processing system SYSb may also move at least one of the processing head21band the stage31based on the results of the coordinate matching operation and the eccentric amount obtaining operation in processing (namely, performing the removal processing on) the workpiece W. For example, the processing system SYSb may rotate the stage31and move the processing head21b(furthermore, the stage31) based on the result of the eccentric amount obtaining operation while irradiating the workpiece W with the processing light EL. As a result, the processing system SYSb is capable of achieving an effect that is same as the effect achievable by the processing system SYSa.

Incidentally, when the processing system SYSb includes the irradiation position change optical member (for example, the Galvano mirror2111) illustrated inFIG.19, the processing system SYSb may change the irradiation position of the processing light EL by the irradiation position change optical member, instead of moving the processing head21. In this case, the processing system SYSb may change the irradiation position of the processing light EL based on the eccentric amount δ obtained from the measured result by the measurement apparatus4.

Incidentally, when the removal processing is performed, the processing system SYSb may irradiate the workpiece W with the processing light EL including the plurality of pulsed lights. For example, the processing system SYSb may irradiate the workpiece W with the processing light EL including the plurality of pulsed lights the ON time of each of which is equal to or shorter than nano seconds.

(3) Processing System SYS in Third Example Embodiment

Next, the processing system SYS in a third example embodiment (in the below described description, the processing system SYS in the third example embodiment is referred to as a “processing system SYSc”) will be described. The processing system SYSc in the third example embodiment is different from the processing system SYSa in the first example embodiment in that it may process the workpiece W by using a tool215c(seeFIG.25described later andFIG.21) for machining the workpiece W in addition to or instead of the processing light EL. Namely, the processing system SYSc is different from the processing system SYSa in that it may perform a machining processing the workpiece W. For example, the processing system SYSc may perform a cutting processing, a grinding processing, a polishing processing or a cutting-off processing on the workpiece W by making the tool contact with the workpiece W. For example, the processing system SYSb may perform the machining processing on the workpiece W so that the shape of the workpiece W is a desired shape. For example, the processing system SYSb may perform the machining processing on the workpiece W to form a desired structure on the workpiece W. For example, the processing system SYSb may perform the machining processing on the workpiece W to form a desired structure on the surface of the workpiece W. For example, the processing system SYSb may perform the machining processing on the workpiece W so that the surface of the workpiece W is polished.

FIG.25andFIG.26illustrates the processing system SYSc.FIG.25is a block diagram that illustrates a system configuration of the processing system SYSc.FIG.26is a cross-sectional view that illustrates a configuration of the processing system SYSc. As illustrated inFIG.25andFIG.26, the processing system SYSc is different from the processing system SYSa in that it may not include the light source5. Furthermore, the processing system SYSc is different from the processing system SYSa in that it may not include the irradiation optical system211. Specifically, the processing system SYSc is different from the processing system SYSa in that it includes a processing unit2cincluding a processing head21cthat does not include the irradiation optical system211instead of the processing unit2including the processing head21that includes the irradiation optical system211. Namely, the processing system SYSc is different from the processing system SYSa in that it may not include a component for irradiating the workpiece W with the processing light EL. Furthermore, the processing system SYSc is different from the processing system SYSa in that it may not include the component for supplying the build materials M. Furthermore, the processing system SYSc is different from the processing system SYSa in that it includes the processing head21cthat includes the tool215cinstead of the processing head21. Another feature of the processing system SYSc may be same as another feature of the processing system SYSa.

The above described processing system SYSc may also move at least one of the processing head21cand the stage31based on the results of the coordinate matching operation and the eccentric amount obtaining operation in processing (namely, performing the removal processing on) the workpiece W. For example, the processing system SYSb may rotate the stage31and move the processing head21(furthermore, the stage31) based on the result of the eccentric amount obtaining operation in while making the tool215ccontact with the workpiece W. As a result, the processing system SYSc is capable of achieving an effect that is same as the effect achievable by the processing system SYSa.

(4) Processing System SYS in Fourth Example Embodiment

Next, with reference toFIG.27, the processing system SYS in a fourth example embodiment (in the below described description, the processing system SYS in the fourth example embodiment is referred to as a “processing system SYSd”) will be described.FIG.27is a block diagram that illustrates a system configuration of the processing system SYSd.

As illustrated inFIG.27, the processing system SYSd in the fourth example embodiment is different from the processing system SYSa in that it includes a cooling apparatus9d. Another feature of the processing system SYSd may be same as another feature of the processing system SYSa.

The cooling apparatus9dis an apparatus that is configured to cool the stage31(the stage31θZ in the fourth example embodiment) on which the workpiece W is placed. Specifically, the workpiece W placed on the stage31θZ is irradiated with the processing light EL. When the workpiece W is irradiated with the processing light EL, a heat is transferred from the processing light to the workpiece W. When the heat is transferred to the workpiece W, a heat is transferred from the workpiece W to the stage31θZ on which the workpiece W is placed. As a result, there is a possibility that a temperature of the stage31θZ is relatively high. The cooling apparatus9dcools the stage31θZ the temperature of which may be possibility relatively high. Incidentally, since the stage31θZ is contained in the inner space of housing8, the cooling apparatus9dis also contained in the inner space of the housing8.

The cooling apparatus9dmay an air-cooled type of cooling apparatus. For example, the cooling apparatus9dmay cool the stage31θZ by supplying a gas to the stage31θZ. Namely, the cooling apparatus9dmay cool the stage31θZ by supplying the gas to a space facing the stage31θZ. The cooling apparatus9dmay cool the stage31θZ by forming a flow of the gas in the space facing the stage31θZ. Next, with reference toFIG.28, one example of the cooling apparatus9dthat cools the stage31θZ by supplying the gas to the space facing the stage31θZ will be described.FIG.28is a cross-sectional view that illustrates one example of a configuration of the cooling apparatus9d.

As illustrated inFIG.28, the cooling apparatus9dmay cool the stage31θZ by supplying the gas to a lower surface312(namely, a surface opposite to an upper surface311) of the stage31θZ having the upper surface311on which the workpiece W is placed. Namely, the cooling apparatus9dmay cool the stage31θZ by supplying the gas to a space SP1facing the lower surface312of the stage31θZ. The lower surface312of the stage31θZ facing the stage31θX. Thus, the space SP1may include at least a part of a space between the lower surface312of the stage31θZ and the stage31θX. However, the cooling apparatus9dmay cool the stage31θZ by supplying the gas to a space facing a surface that is different from the lower surface312of the stage31θZ.

The cooling apparatus9dmay supply the gas to the space SP1from below the stage310Z. When the gas is supplied from below the stage31θZ to the space SP1facing the lower surface312of the stage31θZ, there is a low possibility that the flow of the gas is formed in a space facing the upper surface311of the stage31θZ (namely, a space facing the workpiece W). Thus, the build materials M supplied to the workpiece W placed on the upper surface311is less likely to be blown away by the gas for cooling the stage31θZ. Therefore, the material nozzle212is capable of supplying the build materials M to the workpiece W without being affected by the gas for colling the stage31θZ.

Since the lower surface of the stage31θZ faces the stage31θX, the cooling apparatus9dmay supply the gas to the space SP1through an inside of the stage31θX. The cooling apparatus9dmay supply the gas to the space SP1through a supply path that is formed in the inside of the stage31θX. Specifically, as illustrated inFIG.28, a supply path (in other words, a supply space) SP2for supplying the gas to the space SP1may be formed in an inside of a housing313dof the stage31θX. The supply path SP2is connected to an aperture314dformed at the housing313dto take the gas from an outside of the housing313dto the inside of the housing313d(especially, the supply path SP2). In this case, the cooling apparatus9dmay include a fan91ddisposed at the aperture314d. The fan91dis configured to be driven to take the gas from the outside of the housing313dto the inside of the housing313d(especially, the supply path SP2). Furthermore, the supply path SP2is connected to an aperture315dformed at the housing313dto supply the gas from the supply path SP2in the inside of the housing313dto the space SP1at the outside of the housing313d. The aperture315dis formed at a part (for example, a part located below the stage31θZ) of the housing8facing the space SP1. In this case, the cooling apparatus9dtakes the gas from the outside of the housing313dto the supply path SP2through the fan91ddisposed at the aperture314d, and supplies the taken gas to the space SP1through the supply path SP2and the aperture315d. As a result, the flow of the gas is formed in the space SP1and stage31θZ is cooled by the flow of the gas. Note that the gas supplied to the space SP1in this case may include at least a part of the purge gas supplied from the gas supply source6to an inside of the housing8.

A containing space SP3in which the motor322θZ, which is configured to serve as a rotation mechanism (a movement mechanism) for rotating the stage31θZ, may be formed in the housing313of the stage31θX. A force generated by the motor322θZ is transmitted to the stage31θZ through the rotational shaft321θZ, which is a force transmission mechanism (a movement mechanism) connected to the stage31θZ, and a belt3230Z, which is a force transmission mechanism (a movement mechanism) connecting a rotational axis of the motor3220Z to the rotational shaft321θZ. In this case, at least a part of the rotational shaft321θZ and the belt3230Z may be contained in the containing space SP3. The containing space SP3may be spatially separated from the supply path SP2by a wall member36d. When the containing space SP3is spatially separated from the supply path SP2by the wall member36d, it is prevented that the build materials M enter the containing space SP3(as a result, the motor3220Z and so on is contaminated by the build materials M). Note that the rotational axis of the motor322θZ may be directly connected to the rotational shaft321θZ.

The stage31θX may be connected to the rotational shaft321θX through a reducer324d. For example, the reducer324may connect a lower surface of the stage31θX to the rotational shaft321θX. In this case, there is a possibility that the reducer324dgenerates a heat. The reducer324dmay also be cooled by the flow of the gas for cooling the stage31θZ.

The cooling apparatus9dmay include a wind guide member92d. the wind guide member92dmay be configured to return the gas, which flows from the space SP1to the outside of the space SP1, to the space SP1. As a result, an efficiency of cooling the stage310Z is higher, compared to a case where the cooling apparatus9ddoes not include the wind guide member92d.

As described above, the processing system SYSd is capable of cooling the stage31(for example, the stage31θZ) on which the workpiece W is placed while achieving an effect that is same as the effect achievable by the processing system SYSa.

Note that at least one of the processing system SYSb in the second example embodiment and the processing system SYSc in the third example embodiment may include the cooling apparatus9d.

(5) Modified Example

Next, a modified example of the processing system SYS will be described.

(5-1) Modified Example of Calibration Plate34

In the above described description, the thermosensitive film343formed on the calibration plate34is transparent to the measurement light ML of the measurement apparatus4. However, at least a part of the thermosensitive film343may be opaque to the measurement light ML of the measurement apparatus4.

When the thermosensitive film343is opaque, the thermosensitive film343may cover whole of the calibration pattern CP as illustrated inFIG.29that is a planar view illustrating one example of the calibration plate34. In this case, in an above described calibration operation, the processing system SYS may irradiate the thermosensitive film343with the processing light EL (the step S12inFIG.6), then, measure the exposed pattern PP by measuring the calibration plate34on which the thermosensitive film343is formed (the step S13inFIG.6), then, measure the calibration pattern CP by measuring the calibration plate34from which the thermosensitive film343is removed after the thermosensitive film343is removed (the step S13inFIG.6), and then, associate the processing coordinate system with the stage coordinate system by merging the measured result of the exposed pattern PP and the measured result of the calibration pattern CP.

Alternatively, the thermosensitive film343may cover a part of the calibration pattern CP as illustrated inFIG.30that is a planar view illustrating one example of the calibration plate34. Namely, another part of the calibration pattern CP may not be covered with the thermosensitive film343. In this case, in the above described calibration operation, the processing system SYS may irradiate the thermosensitive film343with the processing light EL (the step S12inFIG.6), then, measure the exposed pattern PP and a part of the calibration pattern CP by measuring the calibration plate34on which the thermosensitive film343is formed (the step S13inFIG.6), then, measure the calibration pattern CP by measuring the calibration plate34from which the thermosensitive film343is removed after the thermosensitive film343is removed (the step S13inFIG.6), and then, associate the processing coordinate system with the stage coordinate system by merging the measured result of the exposed pattern PP and the measured result of the calibration pattern CP. In this case, the processing system SYS is capable of merging the measured result of the exposed pattern PP and the measured result of the calibration pattern CP with relatively high accuracy by using a measured result of a part of the calibration pattern CP that is included in both of the measured result of the exposed pattern PP and the measured result of the calibration pattern CP (namely, a part of the calibration pattern CP that is not covered with the thermosensitive film343). Incidentally, even when the thermosensitive film343is transparent, the thermosensitive film343may cover a part of the calibration pattern CP and may not cover another part of the calibration pattern CP.

Alternatively, the thermosensitive film343may not cover the calibration pattern CP as illustrated inFIG.31that is a planar view illustrating one example of the calibration plate34. Namely, the thermosensitive film343may be formed on a first part of the base member341and the calibration pattern CP may be formed on a second part of the base member341. Incidentally, even when the thermosensitive film343is transparent, the thermosensitive film343may not cover the calibration pattern CP.

(5-2) Modified Example of Calibration Pattern CP

In the above described description, the calibration pattern CP is formed on the calibration plate34. However, the calibration pattern CP may be formed on a member that is different from the calibration plate34. For example, the calibration pattern CP may be formed on a member (for example, a fiducial member) that is placed on the stage31and that is different from the workpiece W. For example, as illustrated inFIG.32toFIG.34, the calibration pattern CP may be formed on the stage31.FIG.32toFIG.34illustrate an example in which the calibration pattern CP is formed on the stage31θZ, however, the calibration pattern CP may be formed on the stage31θX.FIG.32illustrates an example in which the calibration pattern CP is formed on the upper surface311(namely, a surface on which the workpiece W is placed) of the stage31θZ.FIG.33illustrates an example in which the calibration pattern CP is formed on a surface (for example, an outer surface located at an outside of a holding surface3111), which is different from the holding surface3111that faces the workpiece W to actually hold the workpiece W, of the upper surface311of the stage31θZ.FIG.34illustrates an example in which the calibration pattern CP is formed on a side surface316of the stage31θZ.

When the calibration pattern CP is formed on a surface of the stage31θZ that is different from the holding surface3111as illustrated inFIG.33andFIG.34, the processing system SYS is capable of performing each of the coordinate matching operation and the eccentric amount obtaining operation in a state where the workpiece W is placed on the stage310Z. Furthermore, when the calibration pattern CP is formed on a surface of the stage31θZ that is different from the holding surface3111, the processing system SYS is capable of measuring both of at least a part of the calibration pattern CP and at least a part of the workpiece W at the same time in the eccentric amount obtaining operation. Namely, the processing system SYS is capable of measuring at least a part of the calibration pattern CP of the stage31together with at least a part of the workpiece W. Thus, the measurement of the calibration pattern CP by the measurement apparatus4to calculate the rotational axis φZ of the stage31θZ and the measurement of the workpiece W by the measurement apparatus4to calculate the rotational axis φW of the workpiece W may not be performed separately. Thus, a time necessary for the eccentric amount obtaining operation is reducible.

Incidentally, since each of the stages31θX and31θZ are rotated, the calibration pattern CP may include a pattern that is configured to determine the position of at least one of the stages31θX and31θZ. For example, as illustrated inFIG.33andFIG.34, the calibration pattern CP may include an encoder pattern (for example, a grid pattern). The encoder pattern may be an absolute pattern.

Incidentally, when the calibration pattern CP is formed on the stage31, the measurement apparatus4may measure the calibration pattern CP on the stage31in a state where the workpiece W is placed on the stage31.

An existing structural object formed at the stage31may be used as at least a part of the calibration pattern CP in addition to or instead of the dedicated calibration pattern CP. For example, a concave part (for example, an aperture such as a screw hole) formed at the stage31may be used as at least a part of the calibration pattern CP. For example, a convex part (for example, a protruding object) formed at the stage31may be used as at least a part of the calibration pattern CP. In this case, the measurement apparatus4may measure the existing structural object used as at least a part of the calibration pattern CP in a state where the workpiece W is placed on the stage31.

(5-3) Other Modified Example

In the above described description, the processing system SYS obtains (namely, calculates) the rotational axis φZ by measuring the calibration pattern CP. However, the processing system SYS may obtain a rotational axis φ by measuring at least a part of the calibration pattern CP.

In the above described description, the processing system SYS obtains the rotational axis φZ (φX) by measuring the calibration pattern CP. However, the processing system SYS may obtain the rotational axis φZ by measuring at least a part of the stage31(the stage31θZ). For example, the processing system SYS may perform a coordinate matching between a measured result of a three-dimensional shape of the stage31(the stage31θZ) and a designed model of the stage31(the stage31θZ) that is prepared in advance in a measurement coordinate system and may set a rotational axis of the designed model in the measurement coordinate system to be the rotational axis (for example, the rotational axis φZ) that should be obtained.

In the above described description, the processing system SYS obtains the rotational axis φZ (φX). However, the processing system SYS may not obtain the rotational axis φZ (φX). For example, the processing system SYS may measure three-dimensional shapes of at least a part of the stage31and at least a part of the workpiece W in a state where the workpiece W is placed on the stage31, and perform a matching of a measured point cloud information of the stage31and the measured point cloud information of the workpiece W with respect to the designed model of the stage31and a model of the workpiece W in a virtual coordinate system. Then, the processing system SYS may calculate the displacement of the workpiece W due to the rotation of the stage31in the virtual coordinate system and control the movement of the processing head21by using a calculated result.

In the above described description, the workpiece W has a cylindrical shape, however, the shape of the workpiece W is not limited to a rotationally symmetric shape such as the cylindrical shape.

Incidentally, although a detailed description of a holding method by the stage31θZ is omitted in the above described description, the workpiece W may be fixed to a screw hole31θZtp (seeFIG.35A) formed at the stage31θZ through one or more holding clasp317as illustrated inFIG.35AandFIG.35B.

In the above described description, the processing system SYS processes the workpiece W by irradiating the workpiece W with the processing light EL. However, the processing system SYS may process the workpiece W by irradiating the workpiece W with any energy beam. In this case, the processing system SYS may include a beam irradiation apparatus that is configured to emit any energy beam in addition to or instead of the light source5and the irradiation optical system211. At least one of a charged particle beam, an electromagnetic wave and the like is one example of any energy beam. A least one of an electron beam, an ion beam and the like is one example of the charged particle beam.

(6) Supplementary Note

With respect to the example embodiments described above, the following Supplementary Notes will be further disclosed.

A processing system that is configured to process an object by using an energy beam, wherein

the processing system includes:

a holding part that is configured to hold each of the object and a measurement member on which a sensitive film having a sensitivity to the energy beam;

an irradiation apparatus that is configured to irradiate each of the object and the measurement member with the energy beam;

a position change apparatus that is configured to change a relative positional relationship between the irradiation apparatus and the holding part;

a measurement apparatus that is configured to measure at least a part of the measurement member; and

a control apparatus that is configured to control the position change apparatus,

in at least a part of a first period during which the holding part holds the measurement member, the position change apparatus changes the relative positional relationship between the irradiation apparatus and the holding part and the irradiation apparatus irradiates at least a part of the sensitive film of the measurement member with the energy beam,

in at least a part of a second period during which the holding part holds the object, the control apparatus controls the position change apparatus based on a measured result of the measurement member that is irradiated with the energy beam.

The processing system according to the Supplementary Note 1, wherein

the measured result of the measurement member that is irradiated with the energy beam includes a measured result of a part of the sensitive film that reacts to the energy beam.

The processing system according to the Supplementary Note 1 or 2, wherein

a predetermined measurement pattern is formed on the measurement member,

the sensitive film is transparent to a measurement light that is used by the measurement apparatus to measure the measurement member and is formed to cover at least a part of the measurement pattern.

The processing system according to any one of the Supplementary Notes 1 to 3, wherein

a predetermined measurement pattern is formed on the measurement member,

the sensitive film is opaque to a measurement light that is used by the measurement apparatus to measure the measurement member and is formed to cover at least a part of the measurement pattern,

in at least a part of the first period, the measurement apparatus measures the sensitive member that is irradiated with the energy beam and then measures the measurement member from which the sensitive film is removed.

The processing system according to any one of the Supplementary Notes 1 to 4, wherein

in at least a part of the second period, the control apparatus controls the position change apparatus so that the irradiation apparatus irradiates a desired position on the object with the energy beam.

A measurement apparatus that is configured to measure an object that is placed on a rotation apparatus configured to rotate a placed object, wherein

the measurement apparatus includes:

a measurement part that is configured to obtain a first measured result of the object on the rotation apparatus and a second measured result in measuring the object having an attitude that is different from a rotational attitude of the object when the first measured result is obtained; and

a relationship obtaining part that is configured to obtain a relationship between the object and a rotational axis of the rotation apparatus based on the first and second measured results.

A measurement apparatus that is configured to measure an object that is placed on a rotation apparatus configured to rotate a placed object, wherein

the measurement apparatus includes:

a measurement part that is configured to obtain a first measured result of the object on the rotation apparatus and a second measured result in measuring the object having an attitude that is different from a rotational attitude of the object when the first measured result is obtained; and

a difference obtaining part that is configured to obtain, based on the first and second measured results, a translational movement component, in which a rotational movement component is removed, of a movement component of one point of the object when the object is rotated.

An arithmetic apparatus that is connected to a measurement apparatus configured to measure an object that is placed on a rotation apparatus configured to rotate a placed object, wherein

the arithmetic apparatus includes:

a measurement part that is configured to obtain a first measured result of the object on the rotation apparatus and a second measured result in measuring the object having an attitude that is different from a rotational attitude of the object when the first measured result is obtained; and

a relationship obtaining part that is configured to obtain a relationship between the object and a rotational axis of the rotation apparatus based on the first and second measured results.

An arithmetic apparatus that is connected to a measurement apparatus configured to measure an object that is placed on a rotation apparatus configured to rotate a placed object, wherein

the arithmetic apparatus includes:

a measurement part that is configured to obtain a first measured result of the object on the rotation apparatus and a second measured result in measuring the object having an attitude that is different from a rotational attitude of the object when the first measured result is obtained; and

a difference obtaining part that is configured to obtain, based on the first and second measured results, a translational movement component, in which a rotational movement component is removed, of a movement component of one point of the object when the object is rotated.

relationship between the object and a rotational axis of the rotation apparatus based on the first and second measured results.

A processing system that is configured to process an object, wherein

the processing system includes:

a processing apparatus that is configured to process the object;

a rotation apparatus that is configured to rotate a holding part that holds the object;

a measurement apparatus that is configured to measure at least a part of the object held by the holding part; and

a control apparatus that is configured to control the rotation apparatus and the measurement apparatus to rotate the holding part after measuring the object and to measure the object after the rotating the holding part.

The processing system according to the Supplementary Note 10, wherein

the control apparatus obtains a position information of the object held by the holding part based on a first measured result obtained by measuring the object before rotating the holding part and a second measured result obtained by measuring the object after rotating the holding part.

The processing system according to the Supplementary Note 11, wherein

the processing apparatus processes the object based on the position information of the object obtained by the control apparatus.

The processing system according to the Supplementary Note 11 or 12, wherein

the control apparatus controls the rotation apparatus and the measurement apparatus to obtain the second measured result by rotating the object by a rotational angle smaller than 360 degree and measuring the object after the first measured result is obtained.

The processing system according to any one of the Supplementary Notes 11 to 13 further including an angle change apparatus that is configured to change an angle between a rotational axis of the rotation apparatus and a measurement axis of the measurement apparatus.

At least a part of the features of each example embodiment described above may be appropriately combined with at least another part of the features of each example embodiment described above. A part of the features of each example embodiment described above may not be used. Moreover, the disclosures of all publications and United States patents that are cited in each embodiment described above are incorporated in the disclosures of the present application by reference if it is legally permitted.

The present invention is not limited to the above described examples and is allowed to be changed, if desired, without departing from the essence or spirit of the invention which can be read from the claims and the entire specification, and a processing system, which involve such changes, are also intended to be within the technical scope of the present invention.

DESCRIPTION OF REFERENCE CODES