Patent Application
20210291309
The present invention relates to a machine tool system and a determining method with which it can be determined whether a wrong or invalid tool is held in a tool magazine or whether an incorrect tool number or pot number has been assigned.
In machine tool systems which comprise a tool magazine which holds a plurality of tools and a tool exchange device which exchanges tools between the tool magazine and the spindle, the operator visually confirms the tools used for machining one by one and mounts them in the specified pots of the tool magazine, at that time, if the correct tool is not mounted in the tool magazine with the correct tool number or pot number assigned, machining of the workpiece according to the NC machining program cannot be performed, and the tool and the workpiece or machine tool may collide or interfere with each other, damaging the tool, the workpiece, and the machine tool.
Patent Literature 1 describes an automatic collation and recognition device for a tool which, in order to solve such a problem, image-processes an image of a tool captured by an image-capture device, extracts and calculates feature amounts of the tool from the image data, and collates the extracted and calculated feature amount data of the tool with master data of the tool, whereby it can be recognized whether or not the captured tool matches the tool specified by an NC device.
[PTL 1] Japanese Unexamined Patent Publication (Kokai) No. 06-134638
In the automatic collation and recognition device for a tool of Patent Literature 1, the master data is the dimensional data of the tool itself, and the feature amount of the tool extracted from the image data is also the dimensions of characteristic shape of the tool itself. Thus, if the tool is not mounted on the correct tool holder described in the machining program, proper machining cannot be performed according to the machining program, and collision or interference between the tool and the workpiece or machine tool cannot be prevented.
The present invention aims to solve such problems of the prior art, and the object of the present invention is to provide a machine tool system and a tool determining method with which it can be assuredly determined whether or not the tool mounted on the tool magazine is wrong or whether or not the tool is damaged.
In order to achieve the object described above, according to the present invention, there is provided a machine tool system comprising a spindle configured such that a tool is mounted on a distal end part thereof, a tool magazine which holds a plurality of tools, a tool exchange arm which exchanges tools between the tool magazine and the rotating spindle, and a table to which a workpiece is attached, wherein the workpiece is machined by moving the spindle and the table relative to each other in accordance with a machining program, the machine tool system comprising an imaging device which images the tool mounted on a tool holder along with the tool holder, an interference checking device which simulates machining prior to machining using the machining program and shape data of the workpiece, the tool, and a machine tool to confirm the presence or absence of interference between at least the tool and the workpiece, and a controller which acquires the shape data of the tool mounted on the tool holder from the interference checking device, generates a two-dimensional tool model from the acquired shape data of the tool, compares the two-dimensional tool model and an image of the tool imaged by the imaging device, and determines that the tool is invalid when a deviation amount between the two-dimensional tool model and the image data is equal to or greater than a predetermined threshold value.
Further, according to the present invention, there is provided a tool determining method for determining whether or not a valid tool is mounted on a tool magazine of a machine tool system comprising a rotary spindle configured such that a tool is mounted on a distal end part thereof, the tool magazine which holds a plurality of tools, a tool exchange arm which exchanges tools between the tool magazine and the rotary spindle, and a table on which a workpiece is attached, wherein the workpiece is machined by moving the spindle and the table relative to each other in accordance with a machining program to machine the workpiece, the tool determining method comprising the steps of imaging the tool mounted on the tool holder, simulating machining prior to machining using the machining program and shape data of the workpiece, the tool, and a machine tool and acquiring shape data of the tool mounted on a tool holder from an interference checking device which confirms the presence or absence of interference between at least the tool and the workpiece, generating a two-dimensional tool model from the acquired shape data of the tool, comparing the two-dimensional tool model and an image of the tool imaged by an imaging device, and determining that the tool is invalid when a deviation amount between the two-dimensional tool model and the image data is equal to or greater than a predetermined threshold value.
According to the present invention, since the tool is imaged in a state mounted on the tool holder, and the obtained image data and a two-dimensional tool model generated from shape data of the tool in a state in which the tool is mounted on the tool holder from the interference checking unit are compared, it can be assuredly determined whether or not the tool mounted on the tool magazine is the correct tool described in the interference-checked machining program or whether or not the tool is damaged.
The preferred embodiments of the present invention will be described below with reference to the attached drawings.
First, in
The machine tool 1 comprises a bed 12 serving as a base. An X-axis guide rail 19 extending in the X-axis directions, which are the horizontal left and right directions, is affixed to the upper surface of the bed 12. A column 16 is arranged on the upper surface of the X-axis guide rail 19. The column 16 is formed so as to be movable along the A-axis guide rail 19 as indicated by arrow 86. A Y-axis guide rail 20 extending in the Y-axis directions, which are the upward and downward directions, is affixed to the front surface of the column 16. A spindle head 3 is supported by the Y-axis guide rail 20. The spindle head 3 is formed so as to be movable along the Y-axis guide rail 20, as indicated by arrow 85.
Furthermore, a Z-axis guide rail 18 which extends in the Z-axis directions, which are the horizontal frontward and rearward directions, is affixed to the upper surface of the bed 12. A table 14 is arranged on the upper surface of the Z-axis guide rail 18. The workpiece W is affixed to the table 14 via a pallet 15. The table 14 is formed so as to be movable in the Z-axis directions along the Z-axis guide rail 18.
Each of the X-axis, Y-axis and Z-axis feed devices can have a ball screw (not illustrated) extending in the X-axis, Y-axis, or Z-axis direction, and an X-axis, Y-axis, or Z-axis servo motor (not illustrated) connected to one end of the ball screw, and a nut (not illustrated) attached to the column 16, spindle head 3, or table 14 for engaging with the ball screw. Furthermore, a measurement device such as a digital scale (not illustrated) is provided on each of the X-axis, Y-axis, and Z-axis to measure the coordinate positions in the X-axis, Y-axis, and Z-axis directions.
The spindle head 3 supports a spindle 4 so as to be rotatable about an axis of rotation extending in the horizontal frontward and backward directions. A tool 5 for machining the workpiece W is attached to the distal end of the spindle 4. A servo motor (not illustrated) which rotationally drives the spindle 4 is housed in the spindle head 3. The tool 5 has a shape which is rotationally symmetric about its axis or is a solid of revolution, such as a ball end mill, square end mill, face milling cutter, tapping tool, or drill.
The machine tool 1 moves the tool 5 in the X-axis direction and Y-axis direction and moves the workpiece W in the Z-axis direction. Note that the forms of the feed devices are not particularly limited, and the tool can be moved relative to the workpiece by any device. Furthermore, in addition to linear feed axes, the machine tool may have rotary feed axes which rotate about predetermined axes.
The machine tool 1 comprises a tool exchange device 40 which automatically exchanges tools. The machine tool 1 comprises a machining chamber 61 in which the workpiece W is machined and a tool storage chamber 62 for storing the tools 5. The machining chamber 62 and the tool storage chamber 62 are surrounded by a splashguard 54. Furthermore, the machining chamber 61 and the tool storage chamber 62 are separated by a partition wall 51. The bed 12, column 16, spindle head 3, etc., are arranged in the interior of the machining chamber 61. The tool exchange device 40 is arranged in the interior of the tool storage chamber 62. An aperture 51a through which a tool 5 is moved between the machining chamber 61 and the tool storage chamber 62 is formed in the partition wall 51. Furthermore, a shutter 52 for opening and closing the aperture 51a is arranged on the partition wall 51. The shutter 52 is supported by the partition wall 51.
The machine tool 1 has a motor for driving the shutter 52. The shutter 52 is formed so as to be movable relative to the partition wall 51. The shutter 52 of the present embodiment is formed so as to be movable in the Z-axis direction. By moving the shutter 52 to form an opening, movement of the tool 5 through the aperture 51a can be performed.
The tool exchange device 40 has a tool magazine 41 in which a plurality of tools 5 are stored, and a transfer device for transferring a tool 5 between the tool magazine 41 and the spindle 4. The tool magazine 41 of the present embodiment is formed so as to hold tools 5 around a base material formed in a disk shape via a tool holder 45. The tool exchange device 40 includes a motor which rotates the tool magazine 41. The tool magazine 41 rotates as indicated by arrow 87.
The transfer device has a tool shifter 44 and a tool exchange arm 43. The tool shifter 44 moves the tool 5 mounted on the tool holder 45 along with the tool holder 45 between the tool magazine 41 and a tool standby position. By moving the tool shifter 44 in the direction indicated by arrow 88, tools 5 can be removed from the tool magazine 41 and tools 5 can be attached to the tool magazine 41. The tool exchange arm 43 is formed in a stick-like form. The tool exchange arm 43 is provided, on opposing ends thereof, with holding parts 43a for holding the tools 5. The tool exchange device 40 has a motor for rotating the tool exchange arm 43. The tool exchange arm 43 is formed so as to be rotatable about an axis of rotation extending in the Z-axis direction, as indicated by arrow 89.
The standby position is a position in which the tool can be exchanged between the tool exchange arm 43 and the tool shifter 44. Specifically, the tool exchange arm 43 receives the tool from the tool shifter 44 holding the tool in the standby position on one end, which is not holding a tool 5, and transfers a tool 5, on the other end holding the tool 5, to the empty tool shifter 44 standing-by at the standby position.
When the tool 5 is exchange, in the machining chamber 61, the spindle head 3 moves to a predetermined position for exchanging the tool 5. The spindle head 3 is moved to a position in which the tool 5 attached to the spindle 4 can be held by a holding part 43a when the tool exchange arm 43 rotates. The tool 5 which has completed machining is attached to the spindle 4. In the tool storage chamber 62, the tool magazine 41 rotates to a position where the tool 5 to be used next is held by the tool shifter 44. The tool shifter 44 moves the tool 5 to be used next from the tool magazine 41 to the standby position.
Next, the shutter 52 opens and the tool exchange arm 43 rotates. The tool exchange arm 43 holds the tool which has been held by the tool shifter 44 and the tool which has been attached to the spindle 4. Further, by rotating the tool exchange arm 43, the tool 5 to be used next is attached to the spindle 4 and the tool 5 which has completed machining is attached to the tool shifter 44. The tool shifter 44 returns the tool 5 which has been completed machining to the tool magazine 41.
Thus, the tool exchange device 40 can move the tool 5 attached to the spindle 4 to the tool magazine 41. Furthermore, the tool exchange device 40 can move the tool 5 housed in the tool magazine 41 to the spindle 4. After exchange of tools 5 is complete, the tool exchange arm 43 rotates to the original state. After the shutter 52 closes, the subsequent machining begins in the machining chamber 61.
Note that the tool exchange device is not limited to the form described above, and it is sufficient that it be formed so as to be capable of exchanging the tool attached to the spindle and the tool housed in the tool magazine.
The machine tool 1 comprises an imaging device 24 for imaging the tool 5. The imaging device 24 is a backlight system in which the background of the tool 5 becomes brighter while the tool 5 becomes darker in the image of the tool 5. The imaging device 24 images the tool 5 arranged at a predetermined imaging position in the interior of the tool storage chamber 62. The imaging device 24 includes a camera 25. As the camera 25, any camera capable of image processing of the captured image such as a CCD (Charge Coupled Device) camera can be used. The camera 25 of the present embodiment is arranged so as to image the tool 5 when the tool 5 is arranged in the standby position. Note that the imaging position is not limited to the standby position and can be set to any position. In the present embodiment, the tool 5 is mounted on the tool holder 45 when the tool 5 is imaged by the imaging device.
The shutter 52 of the present embodiment functions as a reflective surface arranged on the side opposite the camera 25 with respect to the tool 5 in the direction facing the tool 5 arranged in the standby position from the camera 25. The shutter 52 is arranged behind the tool 5 when viewed from the camera 25. The camera 25 is arranged at a position where substantially the entire background of the tool in the image corresponds to the shutter 52 when the tool 5 is imaged in the standby position. The shutter 52 is arranged at a position where it intersects a straight line connecting the camera 25 and the tool 5 arranged at the standby position. The tool 5 is arranged between the shutter 52 and the camera 25.
The shutter 52 has a reflective surface which reflects light. The reflective surface is formed so as to scatter light. In the present embodiment, the surface of the shutter 52 facing the interior of the tool storage chamber 62 corresponds to the reflective surface. In the shutter 52 of the present embodiment, the reflective surface is painted. The reflective surface is not limited to this form, and it is sufficient that it be formed so as to scatter at least a part of the light incident thereon. In other words, as long as the reflective surface does not have the mirror surface property of reflecting substantially all of the incident light in one direction, the reflecting surface may be any material. For example, rather than the surface being painted, the reflective surface may be exposed metal.
The imaging device 24 comprises an illumination device 26 as a light source for emitting light toward the shutter 52. The illumination device 26 of the present embodiment is an LED (Light Emitting Diode) illuminator. Since the shutter 52 scatters light on the reflective surface, a part of the light emitted from the illumination device 26 is oriented toward the camera 25. The imaging device 24 of the present embodiment employs an indirect illumination method in which the tool 5 is illuminated with the reflected diffusely reflected light, instead of the direct illumination method in which the tool 5 is directly illuminated, as described above. The illumination device 26 is arranged so that an image in which the tool 5 is darker than the background of the tool 5 is captured by the diffusely reflected light reflected by the reflecting surface of the shutter 52.
As shown in
The illumination device 26 preferably has a brightness which makes the entirety of the portion of tool 5 captured by the camera 25 black. In other words, the illumination device 26 is preferably a bright light source which generates a brightness that makes the entirety of the portion of the tool 5 black. Due to this configuration, the shape of the tool 5 in the image is clarified, whereby the shape of the tool 5 can be more accurately measured.
The illumination device 26 can use any illumination other than the LED illumination. By adopting LED illumination as the illumination device 26, the brightness can be increased in a short time. Thus, the time necessary for imaging can be shortened. Further, the use of LED illumination can make the illumination device smaller than other illumination devices.
A plurality of illumination devices may be provided as the light source. For example, the light source may have first and second illumination devices arranged in different positions. By arranging a plurality of illumination devices, the reflective surface can be illuminated from a plurality of directions. As a result, the occurrence of shadows of large foreign objects can be suppressed. In the image, the appearance of black objects in the background of the tool can be suppressed. Alternatively, by arranging a plurality of illumination devices, the background of the tool of the image can be brightened, whereby color unevenness or the like occurring in the background of the tool in the image can be suppressed. As a result, the shape of the tool can be accurately measured.
The machine tool system further comprises a controller 100 for controlling the machine tool 1. The controller 100 can be constituted by providing a CPU (Central Processing Unit), RAM (Random Access Memory), ROM (Read-Only Memory), an electronic data storage device such as a hard disk or a solid state drive (SSD), which are connected to each other via busses, and associated software.
The controller 100 comprises, as primary constituent elements, a determination unit 102, a machine control unit 108, a display unit 114, and an input unit 116. The determination unit 102 has a comparison unit 104 and a storage unit 106. The machine control unit 108 has an interference checking unit 110 and a storage unit 112. The machine control unit 108 can be formed from an NC device, which controls the feed devices of the machine tool 1 and a machine controller for controlling the tool magazine 41, the tool shifter 44, the tool exchange device 40, and the imaging device 24.
In the present embodiment, the interference checking unit 110 of the machine control unit 18 can be constituted by simulation software which is executed by the NC device or machine controller for the machine tool 1. The machining program for machining the workpiece W, shape data of the tool 5 used for machining and the tool holder 45 on which the tool 5 is mounted, shape data of the workpiece W to be machined, and shape data of the machine tool 1 are input into and stored in the storage unit 112 of the machine control unit 108.
The interference checking unit 110 reads the machining program, the shape data of the tool, the shape data of the workpiece, and the shape data of the machine tool 1 from the storage unit 112 prior to actual machining, simulates the machining of the workpiece in accordance with the machining program, and determines, in the simulation, whether or not the tool 5 interferes with the workpiece W or machine tool 1.
The determination unit 102 can comprise a CPU and a storage device independent of the NC device and the machine controller constituting the machine control unit 108, but may be configured as a part of the NC device and/or the machine controller as software.
The comparison unit 104 of the determination unit 102 receives image data of the tool 5 captured by the camera 25 of the imaging device 24 from the imaging device 24. The image data of the tool 5 from the imaging device 24 is associated with a tool number assigned to the imaged tool 5 or a pot number of a tool pot (not illustrated) of the tool magazine 41 on which the tool 5 is mounted.
The comparison unit 104 receives shape data of the tool from the interference checking unit 110. The shape data of the tool from the interference checking unit 110 is associated with the tool number assigned to the associated tool 5 or the pot number of the tool pot (not illustrated) of the tool magazine on which the tool is mounted. The tool number or pot number associated with the shape data of the tool 5 from the interference checking unit 110 is described in the machining program when simulation of machining is performed by the interference checking unit 110.
A threshold value which is described later is stored in the storage unit 106. The threshold value can be, for example, input from an input unit 116. The display unit 114 displays determination results of the determination unit 102 and simulation results of the interference checking unit 110. The display unit 114 can be a liquid crystal display or a touch panel. The input unit 116 can be formed from, for example, various buttons, input keys (not illustrated), etc., provided on the operation panel of the machine tool 1. When the display unit 114 is formed by a touch panel, the display unit 114 constitutes a part of the input unit 116. The input unit 116 may be a personal computer (not illustrated) or a server (not illustrated) connected by a communication network (not illustrated) such as a LAN.
The mode of operation of the present embodiment will be described below with reference to the flowchart shown in
After the operator of the machine tool 1 has mounted the tool 5 on the tool magazine 41, the tool 5 is transferred to an imaging position in accordance with a tool imaging command from the machine control unit 108 of the controller 100 (step S10). Next, the tool 5 is imaged as described above (step S12).
The obtained image data of the tool 5 is output to the comparison unit 104 of the determination unit 102 along with the tool number of the tool 5 or the pot number of the tool pot of the tool magazine 41 in which the tool 5 is mounted. The comparison unit 104 receives shape data of the tool 5 corresponding to the tool number or pot number from the interference checking unit 110. The comparison unit 104 compares the received image data with the tool shape data, in the manner described later (step S14).
Referring to
The binary image 200 of the tool has a portion (tool part) 202 of the tool protruding from the tool holder, and a portion (holder part) 204 of the tool holder which holds the tool. The tool part 202 has a portion 206 of the shank of the tool and a portion 208 of a blade with a cutting edge formed thereon.
The comparison unit 104 can measure the tool length L0′, which is the axial length from the gauge line of the tool holder to the distal end of the tool, the axial length LT′ and diameter DT′ of the tool part 202, and the axial length LH′ and diameter DH′ of the holder part 204 from the image data. Regarding the measurement method, the distance from the camera 25 to the shutter 52 is known, and thus, since the length per pixel of image data can be determined by calculation, each length can be determined by counting the number of pixels corresponding to the axial length LT′ and diameter DT′ of the tool part 202, and the axial length LH′ of the holder part 204.
The two-dimensional tool model 210 has a tool part 212 and a holder part 214, and the tool part 212 has a portion 216 of the shank of the tool and a portion 218 of the blade having the cutting edge formed thereon. The tool shape data can include the tool length L0, which is the axial length from the gauge line of the tool holder to the distal end of the tool, the axial length LT and diameter DT of tool part 212, which is the portion of the tool protruding from the tool holder, and the axial length LH and diameter DH of the holder part 214.
The comparison unit 104 compares the dimensions of the tool obtained form the image data with the dimensions of the tool data. More specifically, the comparison unit 104 calculates at least (1) the difference Δ1=L0′−L0 between the tool length L0′ obtained from image data and the tool length L0 of tool shape data (step S16), (2) the difference Δ2=DT′−DT between the diameter DT′ of the tool part 202 obtained from the image data and the diameter DT of the tool shape data (step S18), and (3) the difference Δ3=diameter DH′−DH between the diameter DH′ of the holder part 204 obtained from image data and the diameter DH of the tool shape data (step S20).
The comparison unit 104 further compares the differences Δ1, Δ2, and Δ3 with the threshold values related to the tool length, the threshold values related to the diameter of the tool part, and the threshold values related to the diameter of the holder part (step S22), respectively and when all of the differences Δ1, Δ2, and Δ3 are less than the respective threshold values (YES in step S22), it is determined that the shape of the tool 5 obtained from the image data matches the shape of the two-dimensional tool model obtained based on the tool shape data obtained from the interference checking unit 110 (step S24). When even one of the differences Δ1, Δ2, and Δ3 is equal to the threshold value or greater than the threshold value (NO in step S22), it is determined that the shape of the tool 5 obtained from the image data does not match the shape of the two-dimensional tool model, and the tool is an invalid tool (step S26). Invalid tools include the case in which the tool, tool holder, tool number or pot number is incorrect, or when a damaged tool is mounted on the tool holder. The controller 100 issues an audio warning such as a warning sound or a visual warning such as displaying a warning on the display unit 114 (step S28), and prevents the tool exchange of the tool, or prevents machining with the tool.
It is possible to inspect whether the correct tool has been assigned the correct tool number or pot number and is held in the tool magazine 41. The tool inspection process described above can be performed when the operator mounts or inserts a tool 5 into the tool magazine 41, or can be performed collectively for all of the tools 5 held by the tool magazine 41 before the start of machining.
The threshold values stored in the storage unit 106 can be one value for all the of the differences Δ1, Δ2 and Δ3, or can be different values for each of the differences Δ1, Δ2 and Δ3. Furthermore, the threshold values in the storage unit 106 may be fixed values, or the operator may be able to edit the values from the input unit 116.
In the example described above, though the image data and the two-dimensional tool model are compared regarding the tool length, the diameter of the tool part and the diameter of the holder part, in addition thereto, the axial length of the tool part and/or the axial length of the holder part may also be compared between the image data and the two-dimensional tool model.
The tool shape data includes a tool length L0, which is the axial length from the gauge line of the tool holder to the distal end of the tool along the central axis O, and in relation to the tool part, the axial length LT and diameter DT of the tool part 302 protruding from the tool holder, and the axial length LH of the holder part 304. The tool shape data can include the diameter of the holder part 304.
In the example shown in
In this example as well, in addition to the tool length, the tool part diameter, and the holder part diameter, the axial length of the tool part and/or the axial length and diameter of each area 306 to 310 of the holder part may be compared between the image data and the two-dimensional tool model.
According to the present embodiment, since a two-dimensional tool model is generated from the image data obtained by imaging the tool in a state in which the tool is mounted on the tool holder and the shape data of the tool in a state in which the tool is mounted on the tool holder from the interference checking unit 110, and the image data is compared with the two-dimensional tool model, it can be assuredly determined whether or not the tool mounted on the tool magazine is the correct tool described in the machining program which has been checked for interference and it can be assuredly determined whether or not the tool is damaged.
1 Machine Tool
5 Tool
24 Imaging Device
25 Camera
40 Tool Exchange Device
41 Tool Magazine
45 Tool Holder
61 Machining Chamber
62 Tool Storage Chamber
100 Controller
102 Determination Unit
104 Comparison Unit
106 Storage Unit
108 Machine Control Unit
110 Interference Checking Unit
112 Storage Unit
114 Display Unit
116 Input Unit
118 Editing Screen
120 Input Box
122 Input Box
124 Input Box
200 Binary Image
202 Tool Part
204 Holder Part
210 Two-Dimensional Tool Model
212 Tool Part
214 Holder Part
300 Two-Dimensional Tool Model
302 Tool Part
304 Holder Part
306 First Area
308 Second Area
310 Third Area
This application is a US National Stage Application under 35 USC 371 of International Patent Application No. PCT/JP2018/026092, filed Jul. 10, 2018, the entire contents of which is incorporated herein by reference.
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/JP2018/026092 | 7/10/2018 | WO | 00 |
