BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to correction methods for dental cutting machines and dental cutting machines.
2. Description of the Related Art
Dental cutting machines that produce dental products by machined objects are known to date. JP2021-178372A, for example, discloses a dental cutting machine including a main shaft that holds and rotates a cutting tool, a holding member that holds a machined object, a rotary mechanism that rotates the holding member to change orientation of the holding member, an X1-direction movement mechanism that moves the holding member and the rotary mechanism in a front-rear direction, and a Y-direction movement mechanism and a Z1-direction movement mechanism that move the main shaft in a left-right direction and a top-bottom direction, respectively.
SUMMARY OF THE INVENTION
In a dental cutting machine, operational errors can occur because of aging or other reasons, resulting in manufacturing of products deviating from dimensions specified in a machining program.
Example embodiments of the present invention provide methods to correct errors in dental cutting machines encountering operational errors. Example embodiments of the present invention also provide dental cutting machines with configurations advantageous for executing the methods to correct errors in dental cutting machines.
A correction method for a dental cutting machine according to an example embodiment of the present invention includes inputting a machining program of a correction piece to a dental cutting machine, mounting a material for the correction piece to the dental cutting machine to which the machining program has been input, machining the correction piece from the material using the dental cutting machine executing the machining program, measuring a dimension of a predetermined portion of the correction piece machined in the machining, calculating a correction value based on the dimension measured in the measuring, and inputting to the dental cutting machine the correction value calculated in the calculating.
With this method, the correction piece is produced and dimensions of a predetermined portion of the correction piece are measured so that it is possible to perform correction to the dental cutting machine based on actual dimensions of the correction piece. Accordingly, operational errors of the dental cutting machine can be corrected.
A dental cutting machine according to an example embodiment of the present invention includes a tool holder to hold a cutting tool, a workpiece holder to hold a machined object, a mover to move at least one of the tool holder and the workpiece holder to move the cutting tool relative to the workpiece holder, and a controller configured or programmed to control the mover and to include a program register in which a machining program of a correction piece to correct a position of the mover is registered, a machining controller configured or programmed to control the mover based on the machining program to machine the correction piece, an input interface to which a measurement result of a dimension of a predetermined portion of the correction piece is input, a calculator configured or programmed to calculate a correction value to be set in the mover based on the result input to the input interface; and a corrector configured or programmed to set the correction value calculated in the calculator in the mover.
In this dental cutting machine, the program register in which the machining program of the correction piece is previously registered, the calculator that calculates the correction value when a measurement result of dimensions of the correction piece is input, and the corrector that sets the calculated correction value to the mover make it possible to perform correction of the dental cutting machine easily.
The above and other elements, features, steps, characteristics and advantages of the present invention will become more apparent from the following detailed description of the example embodiments with reference to the attached drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a cutting machine according to an example embodiment of the present invention.
FIG. 2 is a plan view of a machined object and an adaptor.
FIG. 3 is a longitudinal cross-sectional view of the cutting machine when seen from the left.
FIG. 4 is a plan view of a workpiece holder and a rotator.
FIG. 5 is a block diagram of the cutting machine.
FIG. 6 is a flowchart of a first stage.
FIG. 7 is a plan view of a first correction piece.
FIG. 8 is a cross-sectional view of the first correction piece.
FIG. 9 is a schematic view illustrating a thickness of an uncut portion in a case where a rotation angle that is 180 degrees in a machining program is actually (180-01) degrees.
FIG. 10 is a flowchart of a second stage.
FIG. 11 is a plan view of a second correction piece.
FIG. 12 is a perspective view of a measurement piece when seen from the front.
FIG. 13 is a perspective view of the measurement piece when seen from the rear.
FIG. 14 is a schematic view illustrating a case where a position of a cutter in Z-axis directions relative to a rotation shaft is shifted.
FIG. 15 is a schematic view illustrating a case where a position of the cutter in Y-axis directions relative to the rotation shaft is shifted.
DETAILED DESCRIPTION OF THE EXAMPLE EMBODIMENTS
Dental cutting machines according to example embodiments will be described with reference to the drawings. The example embodiments described herein are, of course, not intended to limit the present invention. Elements and features having the same functions are denoted by the same reference characters, and description for the same elements and features will not be repeated or will be simplified as appropriate.
FIG. 1 is a perspective view of a dental cutting machine 10 (hereinafter referred to simply as a “cutting machine 10”) according to an example embodiment of the present invention. In the following description, when the cutting machine 10 is seen from the front, a direction away from the cutting machine 10 will be referred to as forward, and a direction toward the cutting machine 10 will be referred to as rearward. Left, right, up, and down respectively refer to left, right, up, and down when the cutting machine 10 is seen from the front. Characters F, Rr, L, R, U, and D in the drawings represent front, rear, left, right, up, and down, respectively.
The cutting machine 10 according to this example embodiment is a cutting machine that performs machining on a disc-shaped machined object held by an adaptor, for example. FIG. 2 is a plan view of a machined object 1 and an adaptor 5. The cutting machine 10 herein is a device that produces dental products such as crown prosthetics such as crowns, bridges, copings, inlays, onlays, veneers, and custom abutments, artificial teeth, denture bases, and other products, by cutting the machined object 1. The cutting machine 10 according to this example embodiment is a dry-type cutting machine using no coolant.
Examples of materials of the machined object 1 include resins such as PMMA, PEEK, glass fiber reinforced resin, and hybrid resin, ceramic materials such as glass ceramic and zirconia, metal materials such as cobalt-chromium sintered metal, wax, and gypsum. In the case of using zirconia as a material for the machined object 1, semi-sintered zirconia is used, for example. The machined object 1 herein has a disc (disk) shape. The machined object 1 may have another shape such as a block shape (e.g., cube or rectangular solid).
The adaptor 5 holds the disc-shaped machined object 1. The adaptor 5 is a flat-plate adaptor in which a substantially circular insertion hole 5a corresponding to the machined object 1 is located at the center. The machined object 1 is inserted in the insertion hole 5a to be held by the adaptor 5. The machined object 1 is housed in the cutting machine 10 and machined while being held by the adaptor 5.
As illustrated in FIG. 1, the cutting machine 10 includes a box-shaped casing 11. FIG. 3 is a longitudinal cross-sectional view of the cutting machine 10 when seen from the left. As illustrated in FIG. 3, the cutting machine 10 includes a cutter 20 that holds a rod-shaped cutting tool 6 and rotates the cutting tool 6 about an axis, a workpiece holder 30 that holds a machined object 1 (see FIG. 2), a mover 40 that moves the cutter 20 and the workpiece holder 30 to move the cutting tool 6 relative to the workpiece holder 30, and a controller 60 (see FIG. 1). The mover 40 includes a rotator 50 that changes orientation of the workpiece holder 30 relative to the cutting tool 6 in addition to a device that translates the cutter 20 relative to the workpiece holder 30. The cutter 20, the workpiece holder 30, the mover 40 including the rotator 50, and the controller 60 are housed in the casing 11.
As illustrated in FIG. 3, the cutter 20 includes the cutting tool 6 such that the axis thereof extends in predetermined Z-axis directions. The cutter 20 is an example of a tool holder that holds the cutting tool 6. The Z-axis directions herein are oblique top-bottom directions that tilt rearward. The workpiece holder 30 is located below the cutter 20. The workpiece holder 30 is located in a machining chamber 12 in which machining is performed on the machined object 1. As illustrated in FIG. 1, a machining chamber door 13 is attached to a front opening portion of the machining chamber 12 to be freely opened and closed. The mover 40 includes a Z-axis direction mover 40Z that moves the cutter 20 in the Z-axis directions. The mover 40 further includes a Y-axis direction mover 40Y that moves the cutter 20 in Y-axis directions and an X-axis direction mover 40X that moves the workpiece holder 30 and the rotator 50 in X-axis directions. The X-axis directions are orthogonal to the Z-axis directions, and are herein oblique front-rear directions that tilt downward toward the rear. The Y-axis directions are orthogonal to the Z-axis directions and the X-axis directions, and are herein the left-right directions.
As illustrated in FIG. 3, the cutter 20 includes a main shaft 21 that grips and rotates the cutting tool 6. The main shaft 21 includes a spindle unit 22 and a gripper 23 located at a lower end portion of the spindle unit 22. The spindle unit 22 extends in the Z-axis directions. The spindle unit 22 rotates the gripper 23 about an axis parallel to the Z-axis directions. The spindle unit 22 includes a motor. The spindle unit 22 may be connected to, for example, an external motor by a belt or the like. The gripper 23 is, for example, an air-driven collet chuck. The type of the gripper 23 is not particularly limited.
FIG. 4 is a plan view of the workpiece holder 30 and the rotator 50. As illustrated in FIG. 4, the workpiece holder 30 includes a pair of left and rightward arms 31. The adaptor 5 is inserted between the pair of arms 31 to be held by the workpiece holder 30. The workpiece holder 30 herein holds the machined object 1 through the adaptor 5. The workpiece holder 30 may directly hold the machined object 1 without intervention of other members.
The rotator 50 includes a rotator 50A that rotates the workpiece holder 30 about a rotation shaft 51A extending in the X-axis directions, and a rotator 50B that rotates the workpiece holder 30 about a rotation shaft 51B extending in the Y-axis directions. In the following description, regarding rotation of the workpiece holder 30, directions along which the rotation shaft 51A extends will be also referred to as A-axis directions, and rotation about the rotation shaft 51A will be also referred to as rotation about an A axis. The A-axis directions are parallel to the X-axis directions. The rotator 50A will be also referred to as an A-axis rotator 50A. The A-axis rotator 50A includes an A-axis rotation motor 52A that rotates the rotation shaft 51A.
Similarly, in the following description, regarding rotation of the workpiece holder 30, directions along which the rotation shaft 51B extends will be also referred to as B-axis directions, and rotation about the rotation shaft 51B will be also referred to rotation about the B axis. The B-axis directions are parallel to the Y-axis directions. The rotator 50B will be also referred to as a B-axis rotator 50B. The B-axis rotator 50B includes a B-axis rotation motor 52B (see FIG. 5) that rotates the rotation shaft 51B. As illustrated in FIG. 4, the B-axis rotator 50B supports the A-axis rotator 50A, and rotates the A-axis rotator 50A about the B axis. The A-axis rotator 50A supports the workpiece holder 30, and rotates the workpiece holder 30 about the A axis. The rotation range of the A-axis rotator 50A is a full circumference (360 degrees), whereas the rotation range of the B-axis rotator 50B is smaller than 360 degrees. The angles of the rotation shaft 51A and the rotation shaft 51B at which one surface of the machined object 1 extends in the X-axis directions and the Y-axis directions (orthogonal to the Z-axis directions) in a machining program will be hereinafter referred to as 0 degrees. However, this designation is merely defined for convenience.
As illustrated in FIG. 3, the Y-axis direction mover 40Y includes a pair of Y-axis guide rails 41Y extending in the Y-axis directions, a Y-axis direction moving body 42Y slidably engaged with the Y-axis guide rails 41Y, a Y-axis direction driving motor 43Y (see FIG. 5), and an unillustrated ball screw. The Y-axis direction moving body 42Y is movable in the Y-axis directions along the Y-axis guide rails 41Y. The Y-axis direction moving body 42Y supports the Z-axis direction mover 40Z. The Z-axis direction mover 40Z supports the cutter 20 such that the cutter 20 is movable in the Z-axis directions. When the Y-axis direction driving motor 43Y is driven, the ball screw rotates, and the Y-axis direction moving body 42Y, the Z-axis direction mover 40Z, and the cutter 20 move in the Y-axis directions along the Y-axis guide rails 41Y. The Z-axis direction mover 40Z also has a configuration similar to that of the Y-axis direction mover 40Y. The Z-axis direction mover 40Z includes Z-axis guide rails 41Z extending in the Z-axis directions, a Z-axis direction moving body 42Z slidably engaged with the Z-axis guide rails 41Z, a Z-axis direction driving motor 43Z, and an unillustrated ball screw. When the Z-axis direction driving motor 43Z is driven, the ball screw rotates, and the Z-axis direction moving body 42Z and the cutter 20 move in the Z-axis directions.
Although not shown in detail, the X-axis direction mover 40X is located at the right of a right wall 12R of the machining chamber 12. In a manner similar to the Y-axis direction mover 40Y and the Z-axis direction mover 40Z, the X-axis direction mover 40X also includes guide rails extending in the X-axis directions, an X-axis direction moving body slidably engaged with the guide rails, an X-axis direction driving motor 43X (see FIG. 5), and a ball screw. The X-axis direction moving body supports the rotator 50. When the X-axis direction driving motor 43X is driven, the ball screw rotates, and the rotator 50 and the workpiece holder 30 move in the X-axis directions, together with the X-axis direction moving body.
In this example embodiment, the mover 40 moves the cutter 20 in the Z-axis directions and the Y-axis directions and moves the workpiece holder 30 and the rotator 50 in the X-axis directions. However, the configuration of the mover 40 is not limited to the example embodiment described above. It is sufficient for the Z-axis direction mover 40Z to move the cutter 20 in the Z-axis directions relative to the workpiece holder 30 by moving at least one of the cutter 20 and a set of the workpiece holder 30 and the rotator 50, and which of the cutter 20 or the set of the workpiece holder 30 and the rotator 50 is to be moved is not limited. Similarly, it is sufficient for the Y-axis direction mover 40Y to move the cutter 20 in the Y-axis directions relative to the workpiece holder 30 and the rotator 50 by moving at least one of the cutter 20 and a set of the workpiece holder 30 and the rotator 50. It is sufficient for the X-axis direction mover 40X to move the workpiece holder 30 and the rotator 50 in the X-axis directions relative to the cutter 20 by moving at least one of the cutter 20 and a set of the workpiece holder 30 and the rotator 50.
FIG. 5 is a block diagram of the cutting machine 10. As illustrated in FIG. 5, the controller 60 is connected to the spindle unit 22 and the gripper 23 of the cutter 20, the X-axis direction driving motor 43X of the X-axis direction mover 40X, the Y-axis direction driving motor 43Y of the Y-axis direction mover 40Y, the Z-axis direction driving motor 43Z of the Z-axis direction mover 40Z, the A-axis rotation motor 52A of the A-axis rotator 50A, and the B-axis rotation motor 52B of the B-axis rotator 50B, and is configured or programmed to control these elements.
The configuration of the controller 60 is not particularly limited. The controller 60 may be, for example, a microcomputer. A hardware configuration of the microcomputer is not particularly limited. The microcomputer may include, for example, an interface (I/F) that receives cutting data and other data from external equipment such as a host computer, a central processing unit (CPU) that executes an instruction of a control program, a read only memory (ROM) that stores programs to be executed by the CPU, a random access memory (RAM) that is used as a working area where programs are developed, and a storage such as a memory that stores the programs, the data, and so forth.
As illustrated in FIG. 5, the controller 60 is configured or programmed to include a program register 61, a machining controller 62, an input interface 63, a calculator 64, and a corrector 65. In the program register 61, a machining program of a correction piece 100 (see FIGS. 7 and 11) for position correction of the mover 40 is registered. The “position of the mover 40” herein includes positions of the X-axis direction mover 40x, the Y-axis direction mover 40Y, and the Z-axis direction mover 40Z and rotation positions of the A-axis rotator 50A and the B-axis rotator 50B. The “position correction” herein includes correction of coordinates of a specific point such as an origin and correction of adjusting a distance and an angle on coordinates to an actual distance and an actual angle. In a dental cutting machine, operational errors can occur because of aging or other reasons, resulting in manufacturing of products deviating from dimensions specified in a machining program. The position correction of the mover 40 is work of correcting such errors and modifying the state of the cutting machine 10 to produce a product with dimensions as specified in the machining program. The contents of the “position of the mover” and the “position correction” can vary depending on the configuration of the cutter and the contents of correction.
The correction piece 100 is set at a predetermined shape and is a product obtained by cutting the machined object 1, and dimensions of a predetermined portion of the correction piece 100 are measured. The position of the mover 40 is corrected based on measured dimensions of the correction piece 100. The correction piece 100 will be described in detail later. The program register 61 may store machining data of a product other than the correction piece 100.
The machining controller 62 is configured or programmed to control the cutter 20 and the mover 40 based on the machining program and causes the correction piece 100 to be machined. A measurement result of dimensions of a predetermined portion of the correction piece 100 is input to the input interface 63. The calculator 64 calculates a correction value to be set in the mover 40 based on a result input to the input interface 63. The corrector 65 sets the correction value calculated by the calculator 64 in the mover 40. The controller 60 may include other machining parts, but these parts are neither illustrated nor described herein.
The cutting machine 10 may be configured such that a correction value calculated in an external unit based on measured dimensions of the correction piece 100 can be input to the cutting machine 10. In this case, a main portion to calculate a correction value may be, for example, a calculator in which software to calculate a correction value is installed or an operator who performs correction work. A correction method for the cutting machine 10 includes inputting a machining program of the correction piece 100 to the cutting machine 10, mounting a material (machined object 1 herein) for the correction piece 100 to the cutting machine 10 to which the machining program has been input, machining the correction piece 100 from the material by the cutting machine 10 based on the machining program, measuring a dimension of a predetermined portion of the correction piece 100 machined in the machining, calculating a correction value based on the dimension measured in the measuring, and inputting the correction value calculated in the calculating to the cutting machine 10. A main portion or a method that performs each step is not particularly limited.
An example of machining of the correction piece 100 and a correction process of the cutting machine 10 using the correction piece 100 will now be described. The process described below is merely an example, and the correction process of the cutting machine 10 is not limited to this example.
In this example embodiment, the correction process of the cutting machine 10 includes a first stage including a first mounting step, a first machining step, a first measurement step, a first calculation step, and a first input step, and a second stage including a second mounting step, a second machining step, a second measurement step, a second calculation step, and a second input step. The second stage is performed after the first stage. First, the first stage will be described.
FIG. 6 is a flowchart of the first stage. As shown in FIG. 6, the first stage includes a program step S10, a first mounting step S11, a first machining step S12, a first measurement step S13, a first calculation step S14, and a first input step S15. The program step S10 is included in the first stage for convenience of the drawing, but does not need to be performed in every correction work, and basically only needs to be performed once. In the program step S10, a machining program of the correction piece 100 is input to the cutting machine 10. The machining program includes a first machining program for machining a first correction piece 100A (see FIG. 7) produced in the first machining step S12, and a second machining program for machining a second correction piece 100B (see FIG. 11) from the first correction piece 100A in the second stage.
In the first mounting step S11, a material for the correction piece 100, which is a disc-shaped machined object 1 attached to the adaptor 5 herein, is mounted to the cutting machine 10 to which the machining program of the correction piece 100 has been input. The material for the machined object 1 is preferably an easy-cutting material, for example, wax. The easy-cutting material refers a to material having high dimensional reproducibility after cutting and is less likely to cause wear on the cutting tool 6. Mounting orientation (bottom and top, front and rear, and left and right orientations) of the machined object 1 to the cutting machine 10 is not particularly limited.
In the first machining step S12, based on the first machining program, the cutting machine 10 obtains the first correction piece 100A from the machined object 1 by machining. FIG. 7 is a plan view of the first correction piece 100A. FIG. 8 is a cross-sectional view of the first correction piece 100A. As illustrated in FIGS. 7 and 8, in the first correction piece 100A, recesses 101Rr through 101L are machined in the 0 o'clock, 3 o'clock, 6 o'clock, and 9 o'clock positions, with the rearward direction along the X-axis directions considered as the 0 o'clock position. In the following direction, the recess in the 0 o'clock position will be also referred to as a rear recess 101Rr, the recess in the 3 o'clock position will be also referred to as a right recess 101R, the recess in the 6 o'clock position will be also referred to as a front recess 101F, and the recess in the 9 o'clock position will be also referred to as a left recess 101L. The right recess 101R is located rightward of the rotation shaft 51A (represented as the axis A in FIG. 7) of the A-axis rotator 50A in the Y-axis directions, and the left recess 101L is located leftward of the rotation shaft 51A in the Y-axis directions. The right recess 101R and the left recess 101L herein are symmetrically located in the left-right direction with respect to the rotation shaft 51A.
The front recess 101F is located forward of the rotation shaft 51B (represented as the axis B in FIG. 7) of the B-axis rotator 50B in the X-axis directions, and the rear recess 101Rr is located rearward of the rotation shaft 51B in the X-axis directions. The front recess 101F and the rear recess 101Rr are symmetrically located in the front-rear direction (symmetrically in the front-rear direction along the X-axis directions) with respect to the rotation shaft 51B.
FIG. 8 is a longitudinal cross-sectional view of the first correction piece 100A taken along a plane passing through the right recess 101R and the left recess 101L and extending in the Z-axis directions. As illustrated in FIG. 8, a bottom portion 102R of the right recess 101R and a bottom portion 102L of the left recess 101L are flat. The bottom portion 102R of the right recess 101R and the bottom portion 102L of the left recess 101L extend in the X-axis directions and the Y-axis directions, respectively. Although the cross section is not shown, similarly, the bottom portions of the front recess 101F and the rear recess 101Rr are also flat.
As illustrated in FIG. 8, a bottom-side right recess 103R and a bottom-side left recess 103L corresponding to the right recess 101R and the left recess 101L are located on the bottom sides of the right recess 101R and the left recess 101L. A bottom portion 104R of the bottom-side right recess 103R and a bottom portion 104L of the bottom-side left recess 103L are also flat. The right pair of upper and lower bottom portions 102R and 104R defines an upper end and a lower end of an uncut portion between the bottom portions, and defines a thickness TR of the uncut portion. The left pair of upper and lower bottom portions 102L and 104L defines an upper end and a lower end of an uncut portion of the bottom portions, and defines a thickness TL of the uncut portion. Although the cross section is not shown, similar recesses are also located on the bottom sides of the front recess 101F and the rear recess 101Rr.
The first machining program forms one or more first flat surfaces extending in the X-axis directions and the Y-axis directions on each of one side and the other side of the rotation shaft 51A in the Y-axis directions (right side and left side herein) by the cutting tool 6 in a state in which the workpiece holder 30 is held at a predetermined first angle about the rotation shaft 51A of the A-axis rotator 50A. Accordingly, the bottom portion 102R of the right recess 101R and the bottom portion 102L of the left recess 101L are formed as the first flat surfaces. The first machining program herein forms the first flat surfaces 102R and the 102L (bottom portions 102R and 102L) at the right and left of the rotation shaft 51A by the cutting tool 6 in a state in which the workpiece holder 30 is held in a 0-degree position about the rotation shaft 51A. The first angle is not limited to 0 degrees. The first flat surfaces 102R and 102L (bottom portions 102R and 102L) only need to sandwich the rotation shaft 51A and do not need to be symmetrically located in the left-right direction with respect to the rotation shaft 51A.
The first machining program forms second flat surfaces extending in the X-axis directions and the Y-axis directions on the bottom sides of the plurality of first flat surfaces by the cutting tool 6 in a state in which the workpiece holder 30 is held at a second angle shifted from the first angle by 180 degrees. In this manner, the bottom portion 104R of the bottom-side right recess 103R and the bottom portion 104L of the bottom-side left recess 103L are formed as the second flat surfaces. The first machining program herein forms the second flat surfaces 104R and 104L (bottom portions 104R and 104L) on the bottom sides of the first flat surfaces 102R and 102L (bottom portions 102R and 102L) by the cutting tool 6 in a state in which the workpiece holder 30 is held in the 180-degree position about the rotation shaft 51A.
The first machining program also forms the front recess 101F, the rear recess 101Rr, an unillustrated bottom-side front recess, and an unillustrated bottom-side rear recess in a similar manner. In this case, the rotation angle of the B-axis rotator 50B is set at 0 degrees. The work of turning over the machined object 1 is performed by rotation about the A axis by the A-axis rotator 50A.
As illustrated in FIG. 7, the first correction piece 100A has an identification mark 105 for identifying right and left in the Y-axis directions. The identification mark 105 is a recess herein. The identification mark 105 is located near the top-side front recess 101F herein. Accordingly, the front side and the top side of the first correction piece 100A are recognized. As a result, the right side and the left side of the first correction piece 100A can also be recognized. If the right side and the left side of the first correction piece 100A are mistaken, the sign of the correction value is reversed. The identification mark 105 is used to prevent such an error in identifying left and right. The first machining program forms the identification mark 105 to identify one side from the other side in the Y-axis directions, on the first correction piece 100A by the cutting tool 6.
As shown in FIG. 6, in the first measurement step S13, the thicknesses TR and TL in the Z-axis directions between the two top-side bottom portions 102R and 102L and the two bottom-side bottom portions 104R and 104L are measured. This measurement is performed with a micrometer by a person in charge of correction, for example. In the first measurement step S13, the thicknesses in the Z-axis directions between the two top-side bottom portions 102F and 102Rr and the two bottom-side bottom portions are also measured.
As shown in FIG. 6, in the first calculation step S14, based on the dimensions measured in the first measurement step S13, a correction value concerning a rotation angle about the rotation shaft 51A of the A-axis rotator 50A is calculated. The correction value concerning the rotation angle of the A-axis rotator 50A is a correction value to correct the rotation angle based on a ratio of 180 degrees and an actually measured value obtained by determining an actual value for which the machining program specifies 180 degrees.
FIG. 9 is a schematic view showing the thicknesses TR and TL of an uncut portion in a case where a rotation angle of 180 degrees in a counterclockwise direction in the machining program is actually (180-01) degrees. In FIG. 9, the top-side recesses 101R and 101L are shown below the bottom-side recesses 103R and 103L. For simplification, in the example illustrated in FIG. 9, the 0-degree position is correct, and only the 180-degree position is shifted to a negative side by an angle θ1. It should be noted that the shift can occur in the case of the 0-degree position or in both of the cases of the 0-degree position and the 180-degree position. As illustrated in FIG. 9, in the case where the rotation angle of the A-axis rotator 50A is shifted to a negative side, at the 180-degree position in the program, a left portion of the first correction piece 100A at the left of the rotation shaft 51A is located above a right portion of the first correction piece 100A at the right of the rotation shaft 51A in the Z-axis directions (where the left portion and the right portion herein refer to a left portion and a right portion when the bottom side serves as an upper surface, that is, a left portion and a right portion respectively corresponding to left and right in FIG. 9). Thus, the bottom-side right recess 103R (left recess in FIG. 9) is cut more deeply than the bottom-side left recess 103L (right recess in FIG. 9). Accordingly, the thickness TR becomes smaller than the thickness TL. In a case where the rotation angle of the A-axis rotator 50A is shifted to a positive side, the opposite applies.
The thicknesses TR and TL are measured and a difference between the thicknesses is obtained, thus calculating a shift of the rotation angle of the A-axis rotator 50A. In the first calculation step S14, a correction value to correct the shift of the rotation angle of the A-axis rotator 50A is calculated. As shown in FIG. 6, in the first input step S15, the correction value concerning the rotation angle of the A-axis rotator 50A calculated in the first calculation step S14 is input to the cutting machine 10. The terms “calculation” and “input” of a correction value can include automatic calculation and automatic input of a correction value by the cutting machine 10. In this manner, in this example embodiment, the correction value includes a correction value concerning the rotation angle about the rotation shaft 51A of the A-axis rotator 50A, and this correction value is a correction value to eliminate a difference between the thicknesses TR and TL measured in the first measurement step S13. This correction value is set in the cutting machine 10 so that a shift of the rotation angle about the rotation shaft 51A of the A-axis rotator 50A can be corrected.
As shown in FIG. 6, in the first calculation step S14, a correction value concerning a 0-degree position of the B-axis rotator 50B is also calculated. When the 0-degree position of the B-axis rotator 50B is shifted, one of a front portion forward of the rotation shaft 51B or a rear portion rearward of the rotation shaft 51B is located above the other. Thus, for reasons similar to those illustrated in FIG. 9, the recess of an upper one of the front portion and the rear portion is deeper than the other. Accordingly, the uncut portion of the upper one of the front portion and the rear portion is thinner than the other. Thus, an error at the 0-degree position of the B-axis rotator 50B can be obtained by obtaining a thickness difference in the uncut portion between the front portion and the rear portion. The correction value concerning the 0-degree position of the B-axis rotator 50B is an angle to correct this error. In the first input step S15, this correction value is also input to the cutting machine 10. In this example embodiment, in angle correction of the B-axis rotator 50B, correction of adjusting the unit angle as performed in the case of the A-axis rotator 50A is not performed.
After the first stage, the second stage of correction of the cutting machine 10 is performed. FIG. 10 is a flowchart of the second stage. As shown in FIG. 10, the second stage includes a second mounting step S21, a second machining step S22, a second measurement step S23, a second calculation step S24, and a second input step S25.
The second mounting step S21 is performed after the first machining step S12 through the first input step S15. In the second mounting step S21, the rotation position about the Z axis is changed from the first mounting step S11, and the machined object 1 (first correction piece 100A) is mounted to the cutting machine 10. Although described in detail later, the machining program forms the plurality of recesses 101R and 101L on the line L1 passing through the center of the correction piece 100 in the X-axis directions and extending in the Y-axis directions (see FIG. 7) in the first stage, and forms another measurement surface on the same line L1 (see FIG. 11) in the second stage. In the first stage, the recesses 101R and 101L are located on the line L1 so that an error concerning the rotation angle of the A-axis rotator 50A is magnified to be easily measured. In the second stage, the measurement surface (specifically, a first measurement surface 111Z in the Z-axis directions) is located on the line L1 so that the measurement surface is enlarged and, thus, dimensions can be easily measured. To avoid overlapping of the plurality of recesses 101R and 101L formed in the first stage and another measurement surface formed in the second stage, in the second mounting step S21, the rotation position about the Z axis is changed from the first mounting step S11, and the first correction piece 100A is mounted to the cutting machine 10. Rotation angle at this time is, for example, 45 degrees about the Z axis as illustrated in FIG. 11, but the rotation angle does not need to be exact. The rotation angle in the second mounting step S21 is not particularly limited as long as a portion formed in the first stage and a portion formed in the second stage do not overlap each other.
In the case of producing the first correction piece 100A and the second correction piece 100B (except a machined portion of the first correction piece 100A) separately, in the second mounting step S21, not the first correction piece 100A but a new machined object 1 may be mounted to the cutting machine 10. The amount of the machined object 1 used in correction of the cutting machine 10 can be reduced by reusing the first correction piece 100A in the second stage.
In the second machining step S22, based on the second machining program, the cutting machine 10 obtains the second correction piece 100B from the first correction piece 100A by machining. FIG. 11 is a plan view of the second correction piece 100B.
As illustrated in FIG. 11, in the second correction piece 100B, four measurement pieces 100C for measuring dimensions are machined in the direction of 0 o'clock, 3 o'clock, 6 o'clock, and 9 o'clock positions, respectively. The four measurement pieces 100C are separated from the disc for measuring dimensions. The four measurement pieces 100C are the same pieces, and arranged in the same orientation. In addition, to eliminate influence of difference in machining accuracy (e.g., difference caused by backlash) among machining directions, the four measurement pieces 100C are machined in the same direction. The plurality of measurement pieces 100C can be machined under the same conditions without arrangement of the measurement pieces 100C in the same orientation. In the following description, the measurement piece 100C in the 0 o'clock position will be also referred to as a rear measurement piece 100C, the measurement piece 100C in the 3 o'clock position will be also referred to as a right measurement piece 100C, the measurement piece 100C in the 6 o'clock position will be also referred to as a front measurement piece 100C, and the measurement piece 100C in the 9 o'clock position will be also referred to as a left measurement piece 100C. The right measurement piece 100C and the left measurement piece 100C are formed on the line L1. The right measurement piece 100C and the left measurement piece 100C are herein symmetrically located in the left-right direction with respect to the rotation shaft 51A (represented as the axis A in FIG. 11). The front measurement piece 100C and the rear measurement piece 100C are symmetrically located in the front-rear direction (front-rear direction along the X-axis directions) with respect to the rotation shaft 51B (represented as the line L1 in FIG. 11). The measurement pieces 100C are separated from the disc by cutting a support 100D. Although not shown, identification signs are machined on the four measurement pieces 100C.
FIG. 12 is a perspective view of the measurement piece 100C seen from the front. FIG. 13 is a perspective view of the measurement piece 100C seen from the rear. As illustrated in FIGS. 12 and 13, the measurement pieces 100C includes two planes 111X and 112X having different coordinates in the X-axis directions and each extending in the Y-axis directions and the Z-axis directions. These two planes will be hereinafter referred to as a first measurement surface 111X in the X-axis directions and a second measurement surface 112X in the X-axis directions. In the machining program, a coordinate of the first measurement surface 111X in the X-axis directions is a first X coordinate, and a coordinate of the second measurement surface 112X in the X-axis directions is a second X coordinate. The second machining program forms the first measurement surface 111X whose coordinate in the X-axis directions: X coordinate and the second measurement surface 112X whose coordinate in the X-axis directions is the second X coordinate by the cutting tool 6 on the second correction piece 100B.
As illustrated in FIG. 12, in a manner similar to the X-axis directions, in the Y-axis directions, the measurement piece 100C includes two planes 111Y and 112Y having different coordinates in the Y-axis directions and each extending in the X-axis directions and the Z-axis directions. These two planes will be hereinafter referred to as a first measurement surface 111Y in the Y-axis directions and a second measurement surface 112Y in the Y-axis directions. In the machining program, a coordinate of the first measurement surface 111Y in the Y-axis directions is a first Y coordinate, and a coordinate of the second measurement surface 112Y in the Y-axis directions is a second Y coordinate. The second machining program forms the first measurement surface 111Y whose coordinate in the Y-axis directions is the first Y coordinate and the second measurement surface 112Y whose coordinate in the Y-axis directions is the second Y coordinate by the cutting tool 6 on the second correction piece 100B.
In addition, the measurement piece 100C includes a first measurement surface 111Z, a second measurement surface 1122, and a third measurement surface 113Z having different coordinates in the Z-axis directions and each extending in the X-axis directions and the Y-axis directions. In the machining program, a coordinate of the first measurement surface 111Z in the Z-axis directions is a first Z coordinate, a coordinate of the second measurement surface 112Z in the Z-axis directions is a second Z coordinate, and a coordinate of the third measurement surface 113Z in the Z-axis directions is a third Z coordinate. The second machining program forms the first measurement surface 111Z whose coordinate in the Z-axis directions is the first Z coordinate and the third measurement surface 113Z whose coordinate in the Z-axis directions is the third Z coordinate by the cutting tool 6 on the second correction piece 100B. The first measurement surface 111Z and the third measurement surface 113Z are formed in a state in which the workpiece holder 30 is held at a predetermined angle about the rotation shaft 51A. The predetermined angle herein is 0 degrees. The predetermined angle is not limited to 0 degrees.
The second machining program forms the second measurement surface 112Z whose coordinate in the Z-axis directions is the second Z coordinate by the cutting tool 6 in a state in which the workpiece holder 30 is held in the 180-degree position shifted from the 0-degree position by 180 degrees. The second measurement surface 112Z is formed in a state in which the workpiece holder 30 reversely rotates about the A axis by 180 degrees from the state in forming the first measurement surface 111Z and the third measurement surface 113Z. The first Z coordinate and the second Z coordinate may be the same coordinate as long as these coordinates are seen as coordinates in the Z-axis directions. However, the first measurement surface 111Z and the second measurement surface 112Z formed on the measurement piece 100C are located at different positions in the Z-axis directions.
As shown in FIG. 13, the measurement piece 100C includes a first inspection surface 113Y and a second inspection surface 114Y to correct the position of a Y-axis origin relative to the rotation shaft 51A of the A-axis rotator 50A. Each of the first inspection surface 113Y and the second inspection surface 114Y extends in the X-axis directions and the Z-axis directions. The Y-axis coordinate of the first inspection surface 113Y and the Y-axis coordinate of the second inspection surface 114Y are the same in the machining program. The first inspection surface 113Y and the second inspection surface 114Y are arranged side by side in the Z-axis directions.
The second machining program forms the first inspection surface 113Y extending in the Z-axis directions by the cutting tool 6 on the second correction piece 100B in a state in which the workpiece holder 30 is held at a predetermined angle about the rotation shaft 51A of the A-axis rotator 50A and is held in a predetermined position in the Y-axis directions. The predetermined angle of the rotation shaft 51A herein is 0 degrees. The predetermined angle is not limited to 0 degrees. In addition, the second machining program forms the second inspection surface 114Y extending in the Z-axis directions by the cutting tool 6 on the second correction piece 100B in a state in which the workpiece holder 30 is held at an angle shifted from the predetermined angle by 180 degrees and is held in the predetermined position in the Y-axis directions (the same position as when the first inspection surface 113Y is formed). That is, the first inspection surface 113Y and the second inspection surface 114Y are formed with the workpiece holder 30 inversely rotated about the A axis.
In the machining program, the first inspection surface 113Y and the second inspection surface 114Y are flush with each other. If the position of the Y-axis origin relative to the rotation shaft 51A of the A-axis rotator 50A is shifted, in the second correction piece 100B, a shift occurs between the position of the first inspection surface 113Y in the Y-axis directions and the position of the second inspection surface 114Y in the Y-axis directions. As a result, a step occurs between the first inspection surface 113Y and the second inspection surface 114Y.
As shown in FIG. 10, in the second measurement step S23, a distance in the X-axis directions between the first measurement surface 111X and the second measurement surface 112X in the X-axis directions is measured. Although the measurement method thereof is not particularly limited, a distance X1 between the first measurement surface 111X and another surface parallel to the first measurement surface 111X and a distance X2 between the second measurement surface 112X and the another surface may be measured with a micrometer so that a distance between the first measurement surface 111X and the second measurement surface 112X in the X-axis directions can be obtained from a difference between the distances X1 and X2. The distance between the first measurement surface 111X and the second measurement surface 112X in the X-axis directions may be directly measured with, for example, a micrometer. In the second measurement step S23, a distance in the Y-axis directions between the first measurement surface 111Y and the second measurement surface 112Y in the Y-axis directions is measured. As shown in FIG. 10, steps for these axes in the second measurement step S23 will be referred to as a step S23A. In step S23A, an average value is calculated from measured values obtained from the four measurement pieces 100C, and the obtained average value is used as a representative value. The method for obtaining a representative value from the plurality of measured values is not limited to the average value processing. As the representative value of the measured values, a median may be employed, for example.
In the second measurement step S23, a distance in the Z-axis directions between the first measurement surface 111Z and the third measurement surface 113Z in the Z-axis directions is measured. Both the first measurement surface 111Z and the third measurement surface 113Z are formed in the state in which the workpiece holder 30 is held in the 0-degree position. As shown in FIG. 10, this step in the second measurement step S23 will be referred to as step S23B. In step S23B, a distance in the Z-axis directions between measurement surface 112Z and the third measurement surface 113Z in the Z-axis directions may be measured. In step S23B, measured values obtained from the four measurement pieces 100C are averaged. The method for processing a plurality of measured values is not limited to the average value processing.
In the second measurement step S23, a distance in the Z-axis directions between the first measurement surface 111Z and the second measurement surface 112Z in the Z-axis directions is also measured. The first measurement surface 1112 and the second measurement surface 112Z are formed by reversely rotating the workpiece holder 30 about the A axis by 180 degrees. As shown in FIG. 10, this step in the second measurement step S23 will be referred to as step S23C. In step S23C, measured values obtained from the four measurement pieces 100C are averaged. The method for processing a plurality of measured values is not limited to the average value processing.
In addition, in the second measurement step S23, the amount of shift between the first inspection surface 113Y and the second inspection surface 114Y in the Y-axis directions, that is, a height Y1 of a step between the first inspection surface 113Y and the second inspection surface 114Y in the Y-axis directions (see FIG. 15), is measured. As shown in FIG. 10, this step in the second measurement step S23 will be referred to as step S23D. In step S23D, measured values obtained from the four measurement pieces 100C are averaged. The method for processing a plurality of measured values is not limited to the average value processing.
As shown in FIG. 10, in the second calculation step S24, a correction value concerning a distance in the X-axis directions, a correction value concerning a distance in the Y-axis directions, a correction value concerning a distance in the Z-axis directions, a correction value concerning a position of the cutter 20 in the Z-axis directions relative to the rotation shaft 51A of the A-axis rotator 50A, and a correction value concerning a position of the cutter 20 in the Y-axis directions relative to the rotation shaft 51A are calculated. As shown in FIG. 10, the step of calculating a correction value concerning a distance in the X-axis directions and a correction value concerning a distance in the Y-axis directions will be hereinafter referred to as step S24A. The step of calculating a correction value concerning a distance in the Z-axis directions will be hereinafter referred to as step S24B. The step of calculating a correction value concerning a position of the cutter 20 in the Z-axis directions relative to the rotation shaft 51A and the step of calculating a correction value concerning a position of the cutter 20 in the Y-axis directions relative to the rotation shaft 51A will be referred to as step S24C and step S24D, respectively.
The correction values concerning the distances in the X-axis directions and the Y-axis directions in step S24A are herein calculated after correction concerning the rotation angle of the A-axis rotator 50A. In this example embodiment, the correction concerning the rotation angle of the A-axis rotator 50A is performed in the first input step S15 in the first stage. However, the correction values concerning the distances in the X-axis directions and the Y-axis directions do not depend on accuracy of the rotation angle of the A-axis rotator 50A, and thus, the correction values concerning the distances in the X-axis directions and the Y-axis directions may be calculated before correction concerning the rotation angle of the A-axis rotator 50A. In this example embodiment, the steps are performed in the order described above to perform the machining step through the input step as efficiently as possible.
Regarding the X-axis directions, in step S24A, a correction value to adjust the distance between the first measurement surface 111X and the second measurement surface 112X in the machining program to an actually measured value of the distance between the first measurement surface 111X and the second measurement surface 112X (X1-X2 in the case illustrated in FIG. 12) is calculated. The distance between the first measurement surface 111X and the second measurement surface 112X in the machining program is, in other words, a difference in coordinate value between the first X coordinate and the second X coordinate. The correction value of the distance in the X-axis directions is a correction value to adjust the difference in coordinate value between the first X coordinate and the second X coordinate to the distance measured in the second measurement step S23. For example, in a case where the actually measured value is larger than the distance in the machining program, this means that dimensions of the final product are larger than those programmed, and a correction value to reduce the length in the X-axis directions in the machining program (correction value smaller than one) is calculated. The same holds for the Y-axis directions.
In step S24B, a process similar to that in step S24A is performed for the Z-axis directions. In step S24B, a correction value to adjust a distance between the first measurement surface 111Z and the third measurement surface 113Z in the machining program to an actually measured value of the distance between the first measurement surface 111Z and the third measurement surface 113Z is calculated. The correction value concerning the distance in the Z-axis directions does not depend on accuracy of the rotation angle of the A-axis rotator 50A, either. Thus, the correction value concerning the distance in the Z-axis directions may also be calculated before correction concerning the rotation angle of the A-axis rotator 50A. Regarding the distances in the X-axis directions, the Y-axis directions, and the Z-axis directions, correction of a unit distance is performed. If the distances in the X-axis directions, the Y-axis directions, and the Z-axis directions are shifted, a difference between each distance in the machining program and the actually measured value increases in proportion to the distance in the machining program.
As shown in FIG. 10, in step S24C, a correction value concerning the position of the cutter 20 in the Z-axis directions relative to the rotation shaft 51A is calculated. The correction value concerning the position of the cutter 20 in the Z-axis directions is preferably calculated after correction concerning the angle of the workpiece holder 30 and correction of the distance in the Z-axis directions, as in this example embodiment. Calculation of the correction value concerning the position of the cutter 20 in the Z-axis directions may be performed independently of correction of the distance in the Z-axis directions. FIG. 14 is a schematic value illustrating a case where the position of the cutter 20 in the Z-axis directions relative to the rotation shaft 51A is shifted. As illustrated in FIG. 14, if the position of the cutter 20 in the Z-axis directions relative to the rotation shaft 51A is shifted by Z1 (assumed to be shifted by Z1 upward in the Z-axis directions herein), the first measurement surface 111Z is located above the position in the machining program (indicated by chain double-dashed lines) in the Z-axis directions by Z1. The correction value concerning the position of the cutter 20 in the Z-axis directions is the amount of shift of the origin position in the Z-axis directions. Similarly, the second measurement surface 112Z is also located above the position in the machining program by Z1 in the Z-axis directions (where the second measurement surface 112Z is located below the position in the machining program in FIG. 14). Thus, the distance between the first measurement surface 111Z and the second measurement surface 112Z measured in step S23C is larger than the distance between the first measurement surface 111Z and the second measurement surface 112Z in the Z-axis directions in the machining program by twice the value of Z1. The difference between the distance in the machining program and the actually measured value is uniform, independently of the distance in the machining program. The correction value concerning the position of the cutter 20 in the Z-axis directions is a correction value to eliminate a difference between the measured distance between the first measurement surface 111Z and the second measurement surface 112Z and the distance between the first measurement surface 111Z and the second measurement surface 112Z in the Z-axis directions in the machining program. In the case illustrated in FIG. 14, the correction value is a correction value to shift the origin position in the Z-axis directions downward by Z1.
In step S24D, a correction value concerning the position of the cutter 20 in the Y-axis directions relative to the rotation shaft 51A is calculated. The correction value concerning the position of the cutter 20 in the Y-axis directions is preferably obtained after correction concerning the distance in the Y-axis directions in step S24A, as in this example embodiment.
Calculation of the correction value concerning the position of the cutter 20 in the Y-axis directions may be performed independently of correction of the distance in the Y-axis directions. FIG. 15 is a schematic view illustrating a case where the position of the cutter 20 in the Y-axis directions relative to the rotation shaft 51A is shifted. In this example embodiment, a coordinate of the rotation shaft 51A in the Y-axis directions coincides with the origin coordinate in the Y-axis directions (represented as the Z axis in FIG. 15). Thus, as illustrated in FIG. 15, when the origin position in the Y-axis directions is shifted relative to the rotation shaft 51A, the coordinate position in the Y-axis directions relative to the second correction piece 100B changes between the state in which the rotation shaft 51A is located in the 0-degree position and the state in which the rotation shaft 51A is located in the 180-degree position. In step S24D, from an actually measured value Y1 of a step between the first inspection surface 113Y and the second inspection surface 114Y having the same coordinate in the Y-axis directions, a shift of the origin position in the Y-axis directions relative to the rotation shaft 51A is calculated. The correction value herein is equal to a half Y½ of a measured dimension Y1 of the step. The correction value is the amount of shift of the origin position in the Y-axis directions. In this manner, the correction value concerning the position of the cutter 20 in the Y-axis directions is a correction value to eliminate the shift measured in step S23D.
As shown in FIG. 10, in step S25, the correction value calculated in the second calculation step S24 is input to the cutting machine 10. In this manner, the distance in the X-axis directions, the distance in the Y-axis directions, the distance in the Z-axis directions, the position of the cutter 20 in the Z-axis directions relative to the rotation shaft 51A, and the position of the cutter 20 in the Y-axis directions relative to the rotation shaft 51A are corrected. This configuration enables a product as designed according to the machining program can be produced again.
OTHER EXAMPLE EMBODIMENTS
The cutting machines and the correction methods of the cutting machines according to the above example embodiments have been described. The techniques disclosed here can be carried out as other example embodiments. For example, the shape of the correction pieces and the correction work described above are merely examples, and can change depending on the configuration of the cutting machine. Considering the configuration of the cutting machine, correction of portions that may include errors and correction of portions where errors are less likely to occur may be omitted. Correction not performed in the example embodiments described above may be performed when it is preferable to perform the correction in consideration of the configuration of the cutting machine.
The configuration of the cutting machine is not particularly limited. For example, in the example embodiments described above, the A-axis rotator 50A and the B-axis rotator 50B are mounted on the X-axis direction moving body and moves along the X-axis directions together with the X-axis direction moving body. Thus, the origin position in the X-axis directions relative to the A-axis rotator 50A is less likely to be shifted, and does not need correction. Alternatively, the A-axis rotator and the B-axis rotator may not be moved by the X-axis direction mover. For example, the A-axis rotator and the B-axis rotator may be fixed and the cutting tool may move also in the X-axis directions. In this case, the origin position in the X-axis directions relative to the rotation shaft (e.g., rotation shaft 51B) of the rotator may be corrected. The rotator may not change orientation of the workpiece holder and may change orientation of the cutting tool.
Unless otherwise specified, the example embodiments and modifications thereof do not limit the present invention. For example, the machined object may not be held by the cutting machine through the adaptor, and may be held directly by the cutting machine. The machined object as a material for the correction piece may not be a disk-shaped disc.
While example embodiments of the present invention have been described above, it is to be understood that variations and modifications will be apparent to those skilled in the art without departing from the scope and spirit of the present invention. The scope of the present invention, therefore, is to be determined solely by the following claims.
Patent Application
20250041032
