This application claims the benefit of Japanese Patent Application Number 2005-101479 filed on Mar. 31, 2005, the entirety of which is incorporated by reference.
1. Field of the Invention
The present invention relates to a method for correcting thermal displacement that varies depending on a position of a tool or a workpiece in a machine tool.
2. Description of the Related Art
In a machining process of a machine tool, the machine tool and a workpiece are subject to thermal deformation due to changes of the environmental temperature of a room, heat emitted from the machine tool, and cutting heat. This thermal displacement leads to machining dimension error. As a method to reduce the dimension error, from a mechanical or structural point of view, methods to maintain a constant temperature of the machine and the workpiece have been proposed, for example, by installing the machine in a temperature-controlled room, and controlling the temperature of the cutting fluid. However, these methods require higher running costs and further have a problem in that it is difficult to set a standard temperature of the cutting fluid.
On the other hand, from the viewpoint of electrical control, a method to estimate and correct thermal displacement from temperature information or NC unit information has been proposed. The applicant of the present invention disclosed an example of this method in Japanese Published Unexamined Patent Application No. 2001-341049. This particular method includes the steps of detecting the coordinate data of machining point, that is, the coordinate data of the cutting edge position in machining (hereinafter, it is simply referred to as “cutting edge coordinate data”), and estimating thermal displacement in accordance with the coordinate data of the machining point and temperature information.
Japanese Published Examined Patent Application No. 06-61674 discloses another method that estimates the thermal displacement in accordance with the difference between a main spindle position and a standard position, as well as temperature information. Further, a document Katagijutsu (that means “die/mold technology”), Volume 18, Issue 8, Pages 44-45 discloses another method for estimating thermal displacement generated on a table of a double-column machining center in accordance with temperature information and positional information.
The above-described methods for estimating thermal displacement in accordance with temperature information or positional information from an NC unit work effectively only when a workpiece is cut on a lathe in which the fixed position of a workpiece is defined as the center of the main spindle, or only when a small workpiece is disposed on a table of a machining center and so on. However, when a relatively large workpiece such as a mold is cut, there is a problem that the thermal displacement of the workpiece varies depending on its fixed position on a table.
In
Moreover, in machining a relatively large workpiece such as a mold, when the workpiece is disposed at a place whose environmental temperature is different, there might be another problem in that the dimension and configuration of the workpiece might be different from the desired ones due to thermal deformation caused by a temperature change of the workpiece, even if the workpiece is machined in a uniform environmental temperature, such as a temperature-controlled room for example, wherein no thermal displacement is generated on the machine tool and the workpiece.
In order to solve the above problems, a method for correcting thermal displacement in accordance with a first aspect of the present invention includes the steps of: detecting temperature of each component of a machine tool; converting the detected temperature into numerical values, and estimating an amount of thermal displacement based on the numerical values of temperature and the coordinate data of the cutting edge position using a computing equation.
Moreover, the step of estimating an amount of thermal displacement further includes the steps of: presetting the coordinate data of a fixed position of the workpiece on a table (hereinafter, it is simply referred to as “the coordinate data of the fixed position” or “the coordinate data of the fixed position of the workpiece,”); computing the following values using the coordinate data of the fixed position of the workpiece:
(A) an amount of displacement of the fixed position of the workpiece at a current cutting edge position as ΔAB1,
(B) an amount of displacement of the workpiece between its fixed position and the current cutting edge position as ΔC1, and computing a sum of ΔAB1 and ΔC1 to define an estimated value.
An amount of correction of the coordinate data of the cutting edge position=−(ΔAB1+ΔC1) [Equation 1]
wherein,
ΔAB1: an amount of displacement of the fixed position of the workpiece at a current cutting edge position
ΔC1: an amount of displacement of the workpiece between its fixed position and the cutting edge position
In addition, a method for correcting thermal displacement in accordance with a second aspect of the present invention is characterized by the following steps of:
computing an amount of displacement of the fixed position of the workpiece at the positive end position of moving distance of a cutting edge with respect to a table (hereinafter, it is simply referred to as “stroke” or “cutting stroke”) as ΔAB2, and an amount of displacement of the fixed position of the workpiece at the negative end position of cutting stroke as ΔAB3 instead of ΔAB1 described above; computing an amount of displacement of the workpiece between the fixed position and the positive end position of the cutting stroke as ΔC2, and an amount of displacement of the workpiece between the fixed position and the negative end position of the cutting stroke as ΔC3 instead of ΔC1 described above; computing a sum of ΔAB2 and ΔC2 to define an estimated value at the positive end of the cutting stroke, and a sum of ΔAB3 and ΔC3 to define an estimated value at the negative end of the cutting stroke, and using two-point correction function of a servo system.
An amount of correction at the positive end of the cutting stroke=−(ΔAB2+ΔC2) [Equation 2]
An amount of correction at the negative end of the cutting stroke=−(ΔAB3+ΔC3) [Equation 3]
wherein:
ΔAB2: an amount of displacement of the fixed position of the workpiece at the positive end position of the cutting stroke
ΔAB3: an amount of displacement of the fixed position of the workpiece at the negative end position of the cutting stroke
ΔC2: an amount of displacement of the workpiece between the fixed position and the positive end position of the cutting stroke
ΔC3: an amount of displacement of the workpiece between the fixed position and the negative end position of the cutting stroke
It should be noted that the present invention can be easily embodied, for example, by providing an NC machine tool (a machining center) shown in
According to a third aspect of the present invention, as a more concrete method, an amount of displacement ΔAB1 is obtained from Equation 4 by computing a sum of ΔA1, an amount of displacement of a scale between the current cutting edge position and a scale detector position (shown as A1 in
ΔAB1=(ΔA1+ΔB) [Equation 4]
wherein,
ΔA1=(a temperature for estimating thermal displacement that is obtained based on a temperature of a scale and a standard temperature)×(the coordinate data of the cutting edge position−the coordinate data of the scale detector position)×(a coefficient of linear thermal expansion of the scale) [Equation 5]
ΔB=(a temperature for estimating thermal displacement that is obtained based on a temperature of a table and a standard temperature)×(the coordinate data of the scale detector position−the coordinate data of the fixed position of the workpiece)×(a coefficient of linear thermal expansion of the table) [Equation 6]
Further according to a fourth aspect of the present invention, an amount of displacement ΔC1 (shown as C1 in
ΔC1=(a temperature for estimating thermal displacement that is obtained based on a temperature of the workpiece and a standard temperature)×(the coordinate data of the fixed position of the workpiece−the coordinate data of the cutting edge position)×(a coefficient of linear thermal expansion of the workpiece) [Equation 7]
According to a fifth aspect of the present invention, an amount of displacement ΔAB2 is obtained from Equation 8 by computing a sum of ΔA2, an amount of displacement of the scale between the cutting edge position at the positive end of the cutting stroke and the scale detector position (shown as A2 in
ΔAB2=(ΔA2+ΔB) [Equation 8]
wherein,
ΔA2=(a temperature for estimating thermal displacement that is obtained based on a temperature of a scale and a standard temperature)×(the coordinate data of the positive end position of the cutting stroke−the coordinate data of the scale detector position)×(a coefficient of linear thermal expansion of the scale) [Equation 9]
Similarly, an amount of displacement ΔAB3 is obtained from Equation 10 by computing a sum of ΔA3, an amount of displacement of the scale between the cutting edge position at, the negative end of the cutting stroke and a scale detector position (shown as A3 in
ΔAB3=(ΔA3+ΔB) [Equation 10]
wherein,
ΔA3=(a temperature for estimating thermal displacement that is obtained based on a temperature of a scale and a standard temperature)×(the coordinate data of the negative end position of the cutting stroke−the coordinate data of the scale detector position)×(a coefficient of linear thermal expansion of the scale) [Equation 11]
According to a sixth aspect of the present invention, an amount of displacement ΔC2 (shown as C2 in
ΔC2=(a temperature for estimating thermal displacement that is obtained based on a temperature of the workpiece and a standard temperature)×(the coordinate data of fixed position of the workpiece−the coordinate data of the positive end position of the cutting stroke)×(a coefficient of linear thermal expansion of the workpiece) [Equation 12]
ΔC3=(a temperature for estimating thermal displacement that is obtained based on a temperature of the workpiece and a standard temperature)×(the coordinate data of fixed position of the workpiece−the coordinate data of the negative end position of the cutting stroke)×(a coefficient of linear thermal expansion of the workpiece) [Equation 13]
It should be noted that, a standard temperature is set to be a temperature that requires dimensional accuracy of the workpiece, for example, an environmental temperature capable of measuring the dimensional accuracy of the workpiece, or an environmental temperature capable of assembling a product using the workpiece. With this setting, it is possible to machine the workpiece with dimensions that are suitable for the environmental temperature that requires dimensional accuracy, even if the machining process is conducted in a different environment.
Moreover, workpiece information, such as the coordinate data of the fixed position of the workpiece, the coefficient of linear thermal expansion of the workpiece, and the standard temperature (that requires dimensional accuracy of the workpiece) are preferably set for each workpiece by providing a setting screen on an NC unit, or are set by means of an NC program.
By setting the workpiece information such as the coordinate data of the fixed position of the workpiece, the coefficient of linear thermal expansion of the workpiece, and the standard temperature of the workpiece, it is possible to apply a correction that is suitable for environment according to the fixed position of the workpiece, the workpiece material, and a location of a machine. Moreover, by setting the workpiece information via an operation panel, the setting operation becomes easy. Further, by setting the workpiece information using NC program, correction can be applied to an unattended machining process of the workpiece.
The temperature sensors are preferably disposed oil each component of the machine tool, in particular, a component that relatively moves a cutting edge and a workpiece in the axial direction to be corrected. In this embodiment, the temperature sensor 10a is disposed on the bed 1 near a scale to measure a temperature of the scale, the temperature sensor 10b is disposed on the table 4 to measure a temperature of the table, and the temperature sensor 10c is disposed on the workpiece 5 to measure a temperature of the workpiece.
Hereinafter, correction of the thermal displacement in the X-axis direction at the coordinate data of the fixed position of the workpiece shown in
Xlp=6000 mm
Xlm=0 mm
Xw=1500 mm
The first embodiment will be explained based on the flowchart shown in
At S2, the X-coordinates of a current cutting edge position is detected by an NC unit 14. At S3, using a correction amount computing unit 12, the amount of displacement of the scale ΔA1, the amount of displacement of the table ΔB, and an amount of displacement of the workpiece ΔA2 are computed a using Equations 5, 6, and 7, respectively.
Here, as a computing method for obtaining a temperature for estimating the thermal displacement shown in the first term on the right-hand side of Equation 5, there is provided an exponential smoothing filter as shown in the Japanese Published Unexamined Patent Application No. 9-225781 filed by the present applicant. Accordingly, Equation 5 can be expressed as follows.
X7n=Y7n·(X−Xs)·K7 [Equation 5a]
wherein,
Y7n=Y7n−1+(T70n−Y7n−1)·α7
T70=T7−T0
T0=20
wherein,
Xn: nth amount of displacement
Yn: nth temperature for estimating the thermal displacement
Tn: nth input temperature
α: a coefficient of a filter (α7=3.2×10−2)
X: the X-coordinates
Xs: the X-coordinates of a scale detector (=6000 mm)
K: a coefficient of linear thermal expansion (K7=11×10−6)
Subscript 7: a scale value
Subscript 0: a standard value
Similarly, Equations 6 and 7 can be expressed as follows.
X8n=Y8n·(Xs−Xw)·K8 [Equation 6a]
wherein,
Y8n=Y8n−1+(T80n−Y8n−1)·α8
T80=T8−T0
T0=20
X2n=Y2n·(Xw−X)·K2 [Equation 7a]
wherein,
Y2n=Y2−1+(T20n−Y2n−1)·α2
T20=T8−T0
T0=20
wherein,
Xan: nth amount of displacement
Yn: nth temperature for estimating the thermal displacement
Tn: nth input temperature
X: the X-coordinates
Xs: the X-coordinates of a scale detector (=6000 mm)
α: a coefficient of a filter (α8=3.2×10−2, α2=8.3×10−3)
K: a coefficient of linear thermal expansion (K8=11×10−6, K2=11×10−6)
Subscript 8: a table value
Subscript 2: a workpiece value
Subscript 0: a standard value
Then, from Equations 1 and 4, the amount of correction at the X-coordinates XC is computed.
XC=−(X7+X8+X2)
At S4, the NC unit carries out correction of the thermal displacement, moving by the amount of correction XC in the axis direction. At S5, it returns to S1 when correction is continued, or the process is finished when the correction is discontinued.
Another embodiment of the present invention will be explained based on a flowchart of
At S12, with the correction amount computing unit 12, a correction amount XCP at the coordinate data of the positive end position of the cutting stroke is computed based on an amount of displacement of the scale ΔA2 (from Equation 9), an amount of displacement of the table ΔB (from Equation 6), an amount of displacement the workpiece ΔC2 (from Equation 12) using Equations 1 and 8.
XCP=−(X9+X8+X5) [Equation 1b]
X9n=Y9n·(Xlp−Xs)·K9 [Equation 9b]
X8n=Y8n·(Xs−Xw)·K8 [Equation 6b]
X5n=Y5n·(Xw−Xlp)·K8 [Equation 12b]
wherein,
Y9n=Y9n−1+(T90n−Y9n−1)·α9
T90=T9−T0
T0=20
Y8n=Y8n−1+(T80n−Y8n−1)·α8
T80=T8·T0
T0=20
Y5n=Y5n−1+(T50n−Y5n−1)·α5
T50=T5−T0
T0=20
wherein,
Xn: nth amount of displacement
Yn: nth temperature for estimating the thermal displacement
Tn: nth input temperature
α: a coefficient of a filter (α9=3.2×10−2, α8=3.2×10−2, α5=8.3×10−3)
Xs: the X-coordinates of a scale detector (=6000 mm)
K: a coefficient of linear thermal expansion (K9=11=10−6, K8=11×10−6, K5=11×10−6)
Subscript 9: a scale value
Subscript 8: a table value
Subscript 5: a workpiece value
Subscript 0: a standard value
Similarly, a correction amount at the coordinate data of the negative end position of the cutting stroke XCM is computed based on the amount of displacement of the scale ΔA3 (from Equation 11), the amount of displacement of the table ΔB (from Equation 6), and the amount of displacement the workpiece ΔC3 (from Equation 13) using Equations 1 and 10.
XCM=−(X10+X8+X6) [Equation 1c]
X10n=Y10n·(Xlm−Xs)·K10 [Equation 11c]
X8n=Y8n·(Xs−Xw)·K8 [Equation 6c]
X6n=Y6n·(Xw−Xlm)·K6 [Equation 13c]
wherein,
Y10n=Y10n−1+(T100n−Y10n−1)·α10
T100=T10−T0
T0=20
Y8n=Y8n−1+(T80n−Y8n−1)·α8
T80=T8−T0
T0=20
Y6n=Y6n−1+(T60n−Y6n−1)·α6
T60=T6−T0
T0=20
wherein,
Xn: nth amount of displacement
Yn: nth temperature for estimating the thermal displacement
Tn: nth input temperature
α: a coefficient of a filter (α9=3.2×10−2, α8=3.2×10−2, α5=8.3×10−3)
Xs: the X-coordinates of a scale detector (=6000 mm)
K: a coefficient of linear thermal expansion (K9=11×10−6, K8=11××10−6, K5=11×10−6)
Subscript 9: a scale value
Subscript 8: a table value
Subscript 5: a workpiece value
Subscript 0: a standard value
At S13, the computed correction amounts are transmitted to a servo system. In this servo system, the correction amounts at both ends of the cutting stroke are processed with a linear interpolation method and correction is carried out in accordance with the coordinate data of the cutting edge position using a well-known two-point correction method. At S14, it returns to S11 when correction is continued, or the process is finished when the correction is discontinued.
Moreover, it is required that workpiece information, such as the coordinate data of the fixed position of the workpiece, the coefficient of linear thermal expansion of the workpiece, and the standard temperature (that requires dimensional accuracy of the workpiece) are set for each workpiece to be machined. For this reason, by providing a setting screen as shown in
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Number | Date | Country | |
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20060218811 A1 | Oct 2006 | US |