The present invention relates to a machine tool.
The boom of, for example, an excavator sometimes includes a pair of plate members which are disposed in mutually facing postures and in each of which a plurality of holes are formed at predetermined positions for pivotally supporting an arm, a hydraulic cylinder, and the like, and a joint member joining and fixing the plate members to each other. In the case of such a boom, shafts cannot be inserted and supported in the mutually facing holes if the axes of these mutually facing holes are offset from each other. For this reason, after the plate members are disposed in the mutually facing postures and joined and fixed to each other with the joint member, mutually facing blank holes in the plate members are cut to expand their diameters with, for example, a horizontal boring and milling machine with counter spindles or the lie, so that the blank holes are worked and adjusted into worked holes positioned coaxially with each other.
Patent Literature 1: Japanese Patent Application Publication No. 2006-102843
In the case of the boom of an excavator as mentioned above, when the mutually facing blank holes are worked and adjusted into coaxially positioned worked holes, an error greater than or equal to a prescribed value (tolerance) may be present in the distance (pitch) between the axis of one worked hole and the axis of another worked hole. In this case, a hydraulic cylinder or the like cannot be joined between these worked holes, which makes the boom a defective product.
Such a problem is not limited to the case mentioned above where the mutually facing blank holes in the boom of an excavator are worked and adjusted into worked holes by cutting the blank holes to expand their diameters with a horizontal boring and milling machine with counter spindles or the like. The problem possibly occurs like the above case when n blank holes (n is an integer greater than or equal to 3) formed in a workpiece are to be worked and adjusted into worked holes by cutting the blank holes to expand their diameters with a machine tool.
In view of the above, an object of the present invention is to provide a machine tool capable of working and adjusting n blank holes (n is an integer greater than or equal to 3) formed in a workpiece into worked holes by cutting the blank holes to expand their diameters such that the blank holes are worked and adjusted to such optimized positions that the pitch error between the worked holes can be less than or equal to a tolerance.
A machine tool according to the present invention for solving the above problem is a machine tool for working and adjusting n blank holes (n is an integer greater than or equal to 3) formed in a workpiece into worked holes by cutting the blank holes to expand diameters thereof, characterized in that the machine tool comprises: a table on which the workpiece is placed; a spindle capable of detachably holding a tool for cutting the blank holes in the workpiece and measurement means for measuring positions of the blank holes in the workpiece such that the tool and the measurement means are capable of being changed from one another; spindle drive means for rotationally driving the spindle; relative movement means for moving at least one of the table and the spindle to move the tool and the measurement means relative to the workpiece in an X-axis direction, a Y-axis direction, and a Z-axis direction; and arithmetic control means for controlling the relative movement means such that the positions of the blank holes in the workpiece are measured with the measurement means held on the spindle, calculating positions of center axes of the blank holes based on information on the positions of the blank holes measured with the measurement means, calculating a distance between each two center axes of interest among the center axes, in a case where at least one of the calculated distances does not satisfy a prescribed value, calculating optimized positions of the worked holes from minimized values satisfying Inequalities (110-1), (120-1), (130-1), (140-1), (150-1) below based on Equations (100), (110), (120), (130), (140), (150) below, and controlling the spindle drive means and the relative movement means to cut the blank holes with the tool held on the spindle such that the worked holes are formed at the calculated optimized positions of the worked holes.
Here, MXki is a position of a center axis of a blank hole Gk in the X-axis direction, MYki is a position of the center axis of the blank hole Gk in the Y-axis direction, MXko is a position, in the X-axis direction, of a center axis of a circular area where a worked hole Hk is capable of being formed by working and adjusting the blank hole Gk, MYko is a position, in the Y-axis direction, of the center axis of the circular area where the worked hole Hk can be formed by working and adjusting the blank hole Gk, OXk is a position of an axis of the worked hole Hk in the X-axis direction, OYk is a position of the axis of the worked hole Hk in the Y-axis direction, OXks is a designed position of the axis of the worked hole Hk in the X-axis direction, OYks is a designed position of the axis of the worked hole Hk in the Y-axis direction, OXm is a position of an axis of the worked hole Hm in the X-axis direction, OYm is a position of the axis of the worked hole Hm in the Y-axis direction, OXms is a designed position of the axis of a worked hole Hm in the X-axis direction, OYms is a designed position of the axis of the worked hole Hm in the Y-axis direction, Pkm is a designed pitch between the worked holes Hk, Hm, ΔPkm is a calculated pitch error between the worked holes Hk, Hm, ΔXkm is an axis-to-axis error between the worked holes Hk, Hm in the X-axis direction, ΔYkm is an axis-to-axis error between the worked holes Hk, Hm in the Y-axis direction, ΔQk is an amount of offset between the center axis of the blank hole Gk and the calculated axis of the worked hole Hk, ΔTk is a length between the center axis of the circular area where the worked hole Hk is capable of being formed and the calculated axis of the worked hole Hk, EPkm is a tolerance for the pitch error between the worked holes HK, Hm, EXkm is a tolerance for the axis-to-axis error between the worked holes Hk, Hm in the X-axis direction, EYkm is a tolerance for the axis-to-axis error between the worked holes Hk, Hm in the Y-axis direction, EQk is a tolerance for the amount of offset between the center axis of the blank hole Gk and the axis of the worked hole Hk, ETk is a tolerance for the length between the center axis of the circular area where the worked hole Hk is capable of being formed and the axis of the worked hole Hk, WPkm is a weight coefficient for ΔPkm, WXkm is a weight coefficient for ΔXkm, WYkm is a weight coefficient for ΔYkm, WQk is a weight coefficient for ΔQk, and WTk is a weight coefficient for ΔTk.
Also, the machine tool according to the present invention may be characterized in that, in the machine tool described above, the workpiece is a boom of an excavator.
Also, the machine tool according to the present invention may be characterized in that, in the machine tools described above, the machine tool is a horizontal boring and milling machine with counter spindles.
Also, the machine tool according to the present invention may be characterized in that, in the machine tools described above, the measurement means is anyone of an imaging camera and a touch sensor.
Even in the case of a workpiece with a pitch error greater than or equal to its tolerance between worked holes, the machine tool according to the present invention can work and adjust the worked holes to such optimized positions that all the pitch errors can be less than or equal to their respective tolerances. In this way, defective products can be greatly reduced.
Embodiments of a machine tool according to the present invention will be described with reference to the drawings. However, the present invention is not limited only to the following embodiments to be described with reference to the drawings.
A first embodiment of the machine tool according to the present invention will be described with reference to
As illustrated in
On the surfaces of the columns 122, 132 on the table 112 side, spindle heads 123, 133 are provided movably in an Y-axis direction, which is a vertical direction (the direction perpendicular to the plane of the sheet of
Imaging cameras 125, 135, which serve as measurement means, are detachably attached to the spindles 124, 134, respectively. The spindles 124, 134 are each capable of holding any one of the imaging camera 125, 135 and a tool not illustrated for cutting or the like such as a milling cutter so that the imaging camera 125, 135 and the tool can be changed from one another.
As illustrated in
An input unit 141 that inputs various instructions is electrically connected to the input part of the arithmetic control unit 140. The arithmetic control unit 140 is capable of controlling the actuation of the drive motors 113, 126 to 128, 136 to 138 based on information from the input unit 141 and information inputted in advance, and of performing arithmetic operation for controlling the actuation of the drive motors 113, 126, 127, 136, 137 based on information from the imaging cameras 125, 135 and information inputted in advance (details will be described later).
As illustrated in
The blank holes 11A, 11B, 11D, 12A, 123, 12D in the boom 10 are formed in (hollow) cylindrical protruding portions 11a, 11b, 11d, 12a, 12b, 12d, respectively, which protrude outward of the plate members 11, 12 in their thickness direction. The blank holes 11C, 12C in the boom 10 are formed in bracket portions 11c, 12c around their round protruding ends, respectively, the bracket portions 11c, 12c protruding in flush with the surfaces of the plate members 11, 12.
Note that, in this embodiment, components such as the columns 122, 132, the spindle heads 123, 133, the drive motors 113, 126, 127, 136, 137 constitute relative movement means, and components such as the drive motors 126, 138 constitute spindle drive means.
Next, description will be given of actuation of a machine tool 100 according to this embodiment as described above for working and adjusting the blank holes 11A to 11D, 12A to 12D in the boom 10 into worked holes 10A to 10D by cutting the blank holes 11A to 11D, 12A to 12D to expand their diameters.
First, the boom 10 is placed at a prescribed position on the table 112 (S111 in
Then, the input unit 141 inputs information into the arithmetic control unit 140 which instructs imaging of the blank holes 11A to 11D, 12A to 12D in the plate members 11, 12 of the boom 10 with the imaging cameras 125, 135. In response, the arithmetic control unit 140 actuates the drive motors 113, 126, 127, 136, 137 to move the table 112 in the X-axis direction and move the spindles 124, 134 in the Y-axis direction and the Z-axis direction such that the blank holes 11A to 11D, 12A to 12D in the plate members 11, 12 of the boom 10 can be imaged with the imaging cameras 125, 135 (S113 in
Based on information from the imaging cameras 125, 135, the arithmetic control unit 140 finds the positions of the blank holes 11A to 11D, 12A to 12D in the plate members 11, 12 of the boom 10 in the X-axis direction and the Y-axis direction (S114 in
Then, the arithmetic control unit 140 calculates the positions of such center axes 10ai to 10di in the X-axis direction and the Y-axis direction (see
Thereafter, the arithmetic control unit 140 calculates the distance (pitch) between each two center axes of interest among the center axes 10ai to 10di, in particular, four pitches in total including the pitch between the center axes 10ai, 10bi, the pitch between the center axes 10bi, 10ci, the pitch between the center axes 10ci, 10di, the pitch between the center axes 10ai, 10di (S116 in
If all of the pitches are less than or equal to their respective prescribed values (tolerances), the imaging cameras 125, 135, which are attached to the spindles 124, 134, are changed to tools for cutting or the like such as milling cutters (S118 in
Then, the arithmetic control unit 140 controls the actuation of the drive motors 113, 126, 127, 136, 137 to move the table 112 in the X-axis direction and move the spindles 124, 134 in the Y-axis direction and the Z-axis direction and controls the actuation of the drive motors 128, 138 to rotationally drive the spindles 124, 134 such that the blank holes 11A to 11D, 12A to 12D are worked and adjusted by cutting cut with the tools into worked holes 10A to 10D having their axes on the center axes 10ai to 10di (S119 in
On the other hand, if even one of the pitches does not satisfy its prescribed value (tolerance), the arithmetic control unit 140 calculates minimized values satisfying Inequalities (1111-1) to (1114-1) (1141-1) to (1144-1) below based on Equations (1101), (1111) to (1114), (1141) to (1144) below, that is, the arithmetic control unit 140 calculates optimized positions of the center axes 10ai to 10di in the X-axis direction and the Y-axis direction, in other words, optimized positions of the axes of the worked holes 10A to 10D (S121 in
F(OXa,OXb,OXc,OXd,OYa,OYb,OYc,OYd)=(WPAB×ΔPAB2)+(WPBC×ΔPBC2)+(WPCD×ΔPCD2)+(WPAD×ΔPAD2)+(WQA×ΔQA2)+(WQB×ΔQB2)+(WQC×ΔQC2)+(WQD×ΔQD2) (1101)
ΔPAB={(OXb−OXa)2+(OYb−OYa)2}1/2−PAB (1111)
ΔPSC={(OXc−OXb)2+(OYc−OYb)2}1/2−PBC (1112)
ΔPCD={(OXd−OXc)2+(OYd−OYc)2}1/2−PCD (1113)
ΔPAD={(OXa−OXd)2+(OYa−OYd)2}1/2−PAD (1114)
ΔPAB≤EPAB (1111-1)
ΔPBC≤EPBC (1111-2)
ΔPCD≤EPCD (1111-3)
ΔPDA≤EPDA (1111-4)
ΔQA={(OXa−MXai)2+(OYa−MYai)2}1/2 (1141)
ΔQB={(OXb−MXbi)2+(OYb−MYbi)2}1/2 (1142)
ΔQC={(OXc−MXci)2+(OYc−MYci)2}1/2 (1143)
ΔQD={(OXd−MXdi)2+(OYd−MYdi)2}1/2 (1144)
ΔQA≤EQA (1141-1)
ΔQB≤EQB (1142-1)
ΔQC≤EQC (1143-1)
ΔQD≤EQD (1144-1)
Now, the above values will be described.
MXai is the position of the center axis 10ai in the X-axis direction. MYai is the position of the center axis 10ai in the Y-axis direction. MXbi is the position of the center axis 10bi in the X-axis direction. MYbi is the position of the center axis 10bi in the Y-axis direction. MXci is the position of the center axis 10ci in the X-axis direction. MYci is the position of the center axis 10ci in the Y-axis direction. MXdi is the position of the center axis 10di in the X-axis direction. MYdi is the position of the center axis 10di in the Y-axis direction. These are values calculated by the arithmetic control unit 140 based on the information from the imaging cameras 125, 135 such that the positions of the axes of the mutually facing blank holes 11A to 11D, 12A to 12D can coincide with each other, as described above.
OXa is the position of the axis of the worked hole 10A in the X-axis direction. OYa is the position of the axis of the worked hole 10A in the Y-axis direction. OXb is the position of the axis of the worked hole 103 in the X-axis direction. OYb is the position of the axis of the worked hole 10B in the Y-axis direction. OXc is the position of the axis of the worked hole 100 in the X-axis direction. OYc is the position of the axis of the worked hole 100 in the Y-axis direction. OXd is the position of the axis of the worked hole 10D in the X-axis direction. OYd is the position of the axis of the worked hole 10D in the Y-axis direction. These are values calculated by the arithmetic control unit 140 based on Equations (1101), (1111) to (1114), (1141) to (1144) and Inequalities (1111-1) to (1114-1), (1141-1) to (1144-1) above.
PAB is the designed axis-to-axis distance (pitch) between the worked hole 10A and the worked hole 103. PBC is the designed axis-to-axis distance (pitch) between the worked hole 10B and the worked hole 100. PCD is the designed axis-to-axis distance (pitch) between the worked hole 100 and the worked hole 10D. PAD is the designed axis-to-axis distance (pitch) between the worked hole 10A and the worked hole 10D. These are values inputted in advance in the arithmetic control unit 140.
ΔPAB is the difference (pitch error) between the calculated axis-to-axis distance (pitch) between the axes of the worked hole 10A and the worked hole 10B and PAB mentioned above. ΔPBC is the difference (pitch error) between the calculated axis-to-axis distance (pitch) between the axes of the worked hole 10B and the worked hole 10C and PBC mentioned above. ΔPCD is the difference (pitch error) between the calculated axis-to-axis distance (pitch) between the axes of the worked hole 10C and the worked hole 10DC and PCD mentioned above. ΔPAD is the difference (pitch error) between the calculated axis-to-axis distance (pitch) between the axes of the worked hole 10A and the worked hole 10D and PAD mentioned above. These are values calculated by the arithmetic control unit 140.
ΔQA is the length (amount of offset) between the center axis 10ai and the calculated axis of the worked hole 1-0A. ΔQB is the length (amount of offset) between the center axis 10bi and the calculated axis of the worked hole 10B. ΔQC is the length (amount of offset) between the center axis 10ci and the calculated axis of the worked hole 100. ΔQD is the length (amount of offset) between the center axis 10di and the calculated axis of the worked hole 10D. These are values calculated by the arithmetic control unit 140.
EPAB is a tolerance for the pitch error between the worked holes 10A, 10B. EPBC is a tolerance for the pitch error between the worked holes 10B, 10C. EPCD is a tolerance for the pitch error between the worked holes 10C, 10D. EPAD is a tolerance for the pitch error between the worked holes 10A, 10D. These are values inputted in advance in the arithmetic control unit 140.
EQA is a tolerance for the amount of offset between the center axis 10ai and the axis of the worked hole 10A. EQB is a tolerance for the amount of offset between the center axis 10bi and the axis of the worked hole 10B. EQC is a tolerance for the amount of offset between the center axis 10ci and the axis of the worked hole 100. EQD is a tolerance for the amount of offset between the center axis 10di and the axis of the worked hole 10D. These are values inputted in advance in the arithmetic control unit 140.
WPAB is a weight coefficient for ΔPAB mentioned above. WPBC is a weight coefficient for ΔPBC mentioned above. WPCD is a weight coefficient for ΔPCD mentioned above. WPAD is a weight coefficient for ΔPAD mentioned above. These are values greater than or equal to 0 set as appropriate in accordance with various conditions.
WQA is a weight coefficient for ΔQA mentioned above. WQB is a weight coefficient for ΔQB mentioned above. WQC is a weight coefficient for ΔQC mentioned above. WQD is a weight coefficient for ΔQD mentioned above. These are values greater than or equal to 0 set as appropriate in accordance with various conditions.
Here, assume for example that the tolerances EPAB, EPBC, EPcD, EPAD for the pitch errors are each set at ±5 mm and the tolerances EQA, EQB, EQC, EQD for the amounts of offset are each set at 2.5 mm, and that the pitch errors ΔPAB, ΔPBC, ΔPCD, ΔPAD and the amounts of offset ΔQA to ΔQD which do not satisfy their respective Inequalities (1111-1) to (1114-1), (1141-1) to (1144-1) are obtained as a result of calculating MXai to MXdi, MYai to MYdi mentioned above based on the information from the imaging cameras 125, 135 and calculating Equations (1101), (1111) to (1114), (1141) to (1144) mentioned above with the weight coefficients WPAB, WPBC, WPCD, WPAD, WQA to WQD each set at “1.” In this case, the above values are calculated by gradually increasing (e.g. by 0.1) the weight coefficients WPAB, WPBC, WPCD, WPAD, WQA to WQD for the pitch errors ΔPAB, ΔPBC, ΔPCD, ΔPAD and amounts of offset ΔQA TO ΔQD until they satisfy Inequalities (1111-1) to (1114-1), (1141-1) to (1144-1) (see Optimization Example 1 in Tables 1 to 4 below).
Also, assume for example that the pitch errors ΔPAB, ΔPBC, ΔPCD, ΔPAD and the amounts of offset ΔQA TO ΔQD which do not satisfy their respective Inequalities (1111-1) to (1114-1), (1141-1) to (1144-1) are obtained as a result of calculating Equations (1101), (1111) to (1114), (1141) to (1144) mentioned above with the weight coefficients WQA to WQD for the amounts of offset ΔQA to ΔQD each set at “1” and the weight coefficients WPAB, WPBC, WPCD, WPAD for the pitch errors ΔPAB, ΔPBC, ΔPCD, ΔPAD each set at “0” in an attempt to reduce the amounts of offset ΔQA to ΔQD as much as possible, that is, to leave the removal stocks as much as possible. In this case, the above values are calculated by gradually increasing (e.g. by 0.1) the weight coefficients WQA to WQD for the pitch errors ΔPAB, ΔPBC, ΔPCD, ΔPAD until they satisfy Inequalities (1111-1) to (1114-1), (1141-1) to (1144-1) (see Optimization Example 2 in Tables 1 to 4 below).
Also, for example, as illustrated in
OXc≤MXci (1143-2)
OYc≤MYci (1143-3)
As can be seen from Tables 1 to 4, even when the pitch error between the worked holes 10A, 10B (6.860 mm) exceeds its tolerance (±5 mm), the amount of offset can be reduced to or below the tolerance (2.5 mm) and the pitch error can also be reduced to or below the tolerance (i.e. to 3.513 mm), as illustrated in Optimization Example 1 above.
Further, as illustrated in Optimization Example 2 above, the pitch error (6.860 mm) between the worked holes 10A, 10B can of course be reduced to or below the tolerance (i.e. to 4.740 mm), and the amount of offset can also be reduced to a greater extent than in Optimization Example 1.
Furthermore, as illustrated in Optimization Example 3 above, the pitch error between the worked holes 10A, 10B (6.860 mm) can be reduced to or below the tolerance (i.e. to 4.668 mm) without positioning the worked hole 10C on the positive side relative to each blank hole 11C, 12C in the X-axis direction and the Y-axis direction (the rightward direction and the upward direction of
After the arithmetic control unit 140 calculates the optimized positions of the worked holes 10A to 10D as described above, the imaging cameras 125, 135, which are attached to the spindles 124, 134, are changed to tools for cutting or the like such as milling cutters (S122 in
Then, based on the above calculated results, the arithmetic control unit 140 actuates the drive motors 113, 126, 127, 128, 136, 137, 138 to cut the blank holes 11A to 112, 12A to 12D with the tools to expand their diameters, sc that the blank holes 11A to 11D, 12A to 12D are worked and adjusted into the worked holes 10A to 10D in the boom 10 (S123 in
The boom 10 with the blank holes 11A to 11D, 12A to 12D worked and adjusted into the worked holes 10A to 10D as described above has all the pitch errors less than or equal to their respective tolerances. Hence, components such as hydraulic cylinders can be joined between the worked holes 10A to 10D without problems at all.
Thus, with the machine tool 100 according to this embodiment, even when the boom 10 has a pitch error greater than or equal to its tolerance, the worked holes 10A to 10D can be worked and adjusted to such optimized positions that all the pitch errors are less than or equal to their respective tolerances. In this way, defective products can be greatly reduced.
A second embodiment of the machine tool according to the present invention will be described with reference to
As illustrated in
The arithmetic control unit 24C is capable of controlling the actuation of the drive motors 113, 126 to 128, 136 to 138 based on information from the input unit 141 and information inputted in advance, and of performing arithmetic operation for controlling the actuation of the drive motors 113, 126, 127, 136, 137 based on information from the imaging cameras 125, 135 and information inputted in advance (details will be described later).
Next, description will be given of actuation of a machine tool according to this embodiment including the above arithmetic control unit 240.
As in the foregoing embodiment, after performing Steps S111, S112 described above, the input unit 141 inputs information into the arithmetic control unit 240 which instructs imaging of the protruding portions 11a, 11b, 11d, 12a, 12b, 12d and the bracket portions 11c, 12c of the plate members 11, 12 of the boom 10 as well as the blank holes 11A to 11D, 12A to 12D with the imaging cameras 125, 135. In response, the arithmetic control unit 240 actuates the drive motors 113, 126, 127, 136, 137 to move the table 112 in the X-axis direction and move the spindles 124, 134 in the Y-axis direction and the Z-axis direction such that the protruding portions 11a, 11b, 11d, 12a, 12b, 12d and the bracket portions 11c, 12c of the plate members 11, 12 of the boom 10 as well as the blank holes 11A to 11D, 12A to 12D can be imaged with the imaging cameras 125, 135 (S213 in
Based on information from the imaging cameras 125, 135, the arithmetic control unit 240 finds the positions of the blank holes 11A to 11D, 12A to 12D in the plate members 11, 12 of the boom 10 in the X-axis direction and the Y-axis direction and the positions of the protruding portions 11a, 11b, 11d, 12a, 12b, 12d in the X-axis direction and the Y-axis direction. The arithmetic control unit 240 further finds the positions of the axes of round portions 11ca, 12ca of the protruding ends of the bracket portions 11c, 12c in the X-axis direction and the Y-axis direction (S214 in
Then, the arithmetic control unit 240 calculates the positions of the center axes 10ai to 10di in the X-axis direction and the Y-axis direction as in the foregoing embodiment. In addition, the arithmetic control unit 240 calculates the positions, in the X-axis direction and the Y-axis direction, of such center axes that the mutually facing protruding portions 11a, 11b, 11d, 12a, 12b, 12d of the plate members 11, 12 can be coaxial with each other with the smallest amounts of movement, specifically, the positions, in the X-axis direction and the Y-axis direction, of center axes 10ao, 10bo, 10do of circular areas where the worked holes 10A, 10B, 10D can be formed (see
Thereafter, as in the foregoing embodiment, the arithmetic control unit 240 calculates the pitch between each two center axes of interest among the center axes 10ai to 10di (S116 in
If all of the pitches are less than or equal to their respective prescribed values (tolerances), Steps S118, S119 described above are performed as in the foregoing embodiment.
On the other hand, if even one of the pitches does not satisfy its prescribed value (tolerance), the arithmetic control unit 240 calculates minimized values satisfying Inequalities (1111-1) to (1114-1), (1141-1) to (1144-1) above and Inequalities (2151-1) to (2154-1) below based on Equation (2101) below, Equations (1111) to (1114), (1141) to (1144) above as well as Equations (2151) to (2154) below, that is, the arithmetic control unit 240 calculates optimized positions of the center axes 10ai to 10di in the X-axis direction and the Y-axis direction, in other words, optimized positions of the axes of the worked holes 10A to 10D (S221 in
F(OXa,OXb,OXc,OXd,OYa,OYb,OYc,OYd)=(WPAB×ΔPAB2)+(WPBC×ΔPBC2)+(WPCD×ΔPCD2)+(WPAD×ΔPAD2)+(WQA×ΔQA2)+(WQB×ΔQB2)+(WQC×ΔQC2)+(WQD×ΔQD2)+(WTA×ΔTA2)+(WTB×ΔTB2)+(WTC×ΔTC2)+(WTD×ΔTD2) (2101)
ΔTA={(OXa−MXao)2+(OYa−MYao)2}1/2 (2151)
ΔTB={(OXb−MXbo)2+(OYb−MYbo)2}1/2 (2152)
ΔTC={(OXc−MXco)2+(OYc−MYco)2}1/2 (2153)
ΔTD={(OXd−MXdo)2+(OYd−MYdo)2}1/2 (2154)
ΔTA≤ETA (2151-1)
ΔTB≤ETB (2151-2)
ΔTC≤ETC (2151-3)
ΔTD≤ETD (2151-4)
MXao is the position of the center axis 10ao in the X-axis direction. MYao is the position of the center axis 10ao in the Y-axis direction. MXbo is the position of the center axis 10bo in the X-axis direction. MYbo is the position of the center axis 10bo in the Y-axis direction. MXco is the position of the center axis 10co in the X-axis direction. MYco is the position of the center axis 10co in the Y-axis direction. MXdo is the position of the center axis 10do in the X-axis direction. MYdo is the position of the center axis 10do in the Y-axis direction. These are values calculated by the arithmetic control unit 240 based on the information from the imaging cameras 125, 135 such that the positions of the axes of the mutually facing protruding portions 11a, 11b, 11d, 12a, 12b, 12d can coincide with each other and the positions of the axes of the round portions of the protruding ends of the bracket portions 11c, 12c can coincide with each other, as described above.
ΔTA is the length (amount of eccentricity) between the center axis 10ao and the calculated axis of the worked hole 10A. ΔTB is the length (amount of eccentricity) between the center axis 10bo and the calculated axis of the worked hole 10B. ΔTc is the length (amount of eccentricity) between the center axis 10co and the calculated axis of the worked hole 10C. ΔTD is the length (amount of eccentricity) between the center axis 10do and the calculated axis of the worked hole 10D. These are values calculated by the arithmetic control unit 240.
ETA is a tolerance for the amount of eccentricity between the center axis 10ao and the axis of the worked hole 10A. ETB is a tolerance for the amount of eccentricity between the center axis 10bo and the axis of the worked hole 10B. ETC is a tolerance for the amount of eccentricity between the center axis 10co and the axis of the worked hole 10C. ETD is a tolerance for the amount of eccentricity between the center axis 10do and the axis of the worked hole 10D. These are values inputted in advance in the arithmetic control unit 240.
WTA is a weight coefficient for ΔTA mentioned above. WTB is a weight coefficient for ΔTB mentioned above. WTC is a weight coefficient for ΔTC mentioned above. WTD is a weight coefficient for ΔTD mentioned above. These are values greater than or equal to 0 set as appropriate in accordance with various conditions.
In sum, this embodiment takes into consideration not only the amounts of offset of the worked holes 10A to 10D relative to the blank holes 11A to 11D, 12A to 12D but also the amounts of eccentricity relative to the protruding portions 11a, 11b, 11d, 12a, 12b, 12d and the round portions of the bracket portions 11c, 12c.
After this arithmetic control unit 240 calculates the optimized positions of the worked holes 10A to 10D as in the foregoing embodiment, Steps S122, S123 described above are performed. As a result, the blank holes 11A to 11D, 12A to 12D can be worked and adjusted into the worked holes 10A to 10D in the boom 10.
Thus, for the worked holes 10A, 10B, 10D, the amounts of unevenness in the thicknesses of the protruding portions 11a, 11b, 11d, 12a, 12b, 12d in the radial direction can be optimized. For the worked hole 100, the stock allowances for the protruding ends of the bracket portions 11c, 12c can be optimized.
Hence, with this embodiment, it is possible to achieve similar advantageous effects to those by the foregoing embodiment and, in addition, more effectively reduce the decrease in strength of the protruding portions 11a, 11b, 11d, 12a, 12b, 12d and the bracket portions 11c, 12c due to the formation of the worked holes 10A to 10D.
In the foregoing embodiments, the imaging cameras 125, 135 are used to input the information on the blank holes 11A to 11D, 12A to 12D in the plate members 11, 12 of the boom 10, the information on the protruding portions 11a, 11b, 11d, 12a, 12b, 12d, the information on the bracket portions 11c, 12c, and other relevant information into the arithmetic control units 140, 240. Note however that, as another embodiment, it is possible to use, for example, touch probes or the like in place of the imaging cameras 125, 135 to input the information on the blank holes 11A to 11D, 12A to 12D in the plate members 11, 12 of the boom 10, the information on the protruding portions 11a, 11b, 11d, 12a, 12b, 12d, the information on the bracket portions 11c, 12c, and other relevant information into the arithmetic control units 140, 240.
Also, the foregoing embodiments have described the cases where the present invention is applied to a table moving-type horizontal boring and milling machine with counter spindles. However, as another embodiment, it is possible to apply the present invention to, for example, a column moving-type horizontal boring and milling machine with counter spindles. In this case, too, similar advantageous effects to those by the foregoing embodiments can be achieved.
Also, the foregoing embodiments have described the cases where the mutually facing blank holes 11A to 11D, 12A to 12D in the plate members 11, 12 of the boom 10 of the excavator are worked and adjusted into the worked holes 10A to 10D by cutting the blank holes 11A to 11D, 12A to 12D to expand their diameters. However, the present invention is not limited to these cases and is applicable just as the foregoing embodiments to cases where n blank holes (n is an integer greater than or equal to 3) formed in a workpiece are to be worked and adjusted into worked holes by cutting the blank holes to expand their diameters.
In the case of such a workpiece, the arithmetic control means calculates optimized positions of the worked holes from minimized values satisfying Inequalities (110-1), (120-1), (130-1), (140-1), (150-1) below based on Equations (100), (110), (120), (130), (140), (150) below.
In the above equations and inequalities, MXki is the position of the center axis of a blank hole Gk in the X-axis direction; MYki is the position of the center axis of the blank hole Gk in the Y-axis direction; MXko is the position, in the X-axis direction, of the center axis of a circular area where a worked hole Hk is capable of being formed by working and adjusting the blank hole Gk; MYko is the position, in the Y-axis direction, of the center axis of the circular area where the worked hole Hk is capable of being formed by working and adjusting the blank hole Gk; OXk is the position of the axis of the worked hole Hk in the X-axis direction; OYk is the position of the axis of the worked hole Hk in the Y-axis direction; OXks is the designed position of the axis of the worked hole Hk in the X-axis direction; OYks is the designed position of the axis of the worked hole Hk in the Y-axis direction; OXm is a position of an axis of the worked hole Hm in the X-axis direction, OYm is a position of the axis of the worked hole Hm in the Y-axis direction, OXms is the designed position of the axis of a worked hole Hm in the X-axis direction; OYms is the designed position of the axis of the worked hole Hm in the Y-axis direction; Pkm is the designed pitch between the worked holes Hk, Hm; ΔPkm is the calculated pitch error between the worked holes Hk, Hm; ΔXkm is the axis-to-axis error between the worked holes Hk, Hm in the X-axis direction; ΔYkm is the axis-to-axis error between the worked holes Hk, Hm in the Y-axis direction; ΔQk is the amount of offset between the center axis of the blank hole Gk and the calculated axis of the worked hole Hk; ΔTk is the length between the center axis of the circular area where the worked hole Hk is capable of being formed and the calculated axis of the worked hole Hk; EPkm is a tolerance for the pitch error between the worked holes HK, Hm; EXkm is a tolerance for the axis-to-axis error between the worked holes Hk, Hm in the X-axis direction; EYkm is a tolerance for the axis-to-axis error between the worked holes Hk, Hm in the Y-axis direction; EQk is a tolerance for the amount of offset between the center axis of the blank hole Gk and the axis of the worked hole Hk; ETk is a tolerance for the length between the center axis of the circular area where the worked hole Hk is capable of being formed and the axis of the worked hole Hk; WPkm is a weight coefficient for ΔPkm; WXkm is a weight coefficient for ΔXkm; WYkm is a weight coefficient for ΔYkm; WQk weight coefficient for ΔQk; and WTk is a weight coefficient for ΔTk.
Here, ΔPkm mentioned above is the error in the axis-to-axis distance between the worked holes Hk, Hm. On the other hand, ΔXkm, ΔYkm mentioned above are the axis-to-axis errors between the worked holes Hk, Hm in the X- and Y-axis directions, and are values employed in a case where the error between the axes of the worked holes Hk, Hm in the X-axis direction and the error between the axes of the worked holes Hk, Hm in the Y-axis direction are considered individually or only one of these errors in the X-axis direction and the Y-axis direction should be considered.
In short, the foregoing first and second embodiments are cases where n is set at “4,” the amount of offset between the worked holes 10A, 100 and the amount of offset between the worked holes 10B, 10D are omitted, WXkm, WYkm are set at “0,” and, in the foregoing first embodiment, WTk is set at “0.”
As described above, the present invention can handle various cases by optionally selecting, when necessary, those worked holes between which the pitch error is desired to be less than or equal to the tolerance, and optionally selecting various conditions (setting weight coefficients for unnecessary conditions at “0”) in accordance with the state of the workpiece.
Even in the case of a workpiece with a pitch error greater than or equal to its tolerance between worked holes, the machine tool according to the present invention can work and adjust the worked holes to such optimized positions that all the pitch errors can be less than or equal to their respective tolerances. In this way, defective products can be greatly reduced. The machine tool according to the present invention can therefore be utilized significantly beneficially in various working industries.
Number | Date | Country | Kind |
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2013-175233 | Aug 2013 | JP | national |
Filing Document | Filing Date | Country | Kind |
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PCT/JP2014/063781 | 5/26/2014 | WO | 00 |
Publishing Document | Publishing Date | Country | Kind |
---|---|---|---|
WO2015/029517 | 3/5/2015 | WO | A |
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International Search Report with Written Opinion of the International Search Authority of International Application No. PCT/JP2014/063781 dated Jul. 15, 2014 with English Translation. |
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Number | Date | Country | |
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20160209826 A1 | Jul 2016 | US |