This application is a 371 of PCT/JP2011/064410 Jun. 23, 2011.
The present invention relates to a system and a method for measuring a length of a gap between a rotating tool and a workpiece in an ultra-precision cutting and grinding process for manufacturing a metal mold of a fine electronic component or an opto-mechatronics component.
In the leading-edge technologies of recent precision fine die and mold machining, sub-micron machining accuracy has been achieved by using highly accurate machining centers. For the purpose of enhancement of machining accuracy and productivity efficiency, such a technique has been required that measures a tedious and time-consuming tool setting (a gap between a tip end of a tool that is rotating at a high speed and a workpiece) with sub-micron accuracy. Currently, fine machining is carried out by using a small-diameter tool of a machine tool such as a machining center with high accuracy. For the enhancement of the machining accuracy, machining accuracy and machining efficiency may be significantly affected by not only precision of a machine tool but also information regarding a cut-lip end (cutting edge) of the tool on the machine that is important information for determining a position of the tool relative to the workpiece and its in-feed rate. Unfortunately, measurement accuracy handled in an optical non-contact and on-machine tool measurement method that is commercially available is approximately several microns due to the diffraction phenomenon of an emitted light, and this is insufficient for tool measurement with sub-micron measurement accuracy.
In conventional on-machine tool measurement methods, a tool is irradiated with a laser beam, and a light diffracted from the tool is detected, so as to measure a diameter and a cut-lip shape of the tool. If the tool is rotating at a high speed, the frame rate of a camera for acquiring the diffracted light cannot catch up with the rotational speed, which makes the measurement difficult (see Patent Documents 1, 3). Conventional methods using the diffracted light require a reference knife-edge, so that it is necessary to find a relative distance between the reference knife-edge and a workpiece with high accuracy (see Patent Documents 2, 4).
In a fine machining process using a small-diameter tool, the tool is rotating at 10000 rpm or more, and if this rotation is stopped to measure the length of the gap between the tool and the workpiece, the machining efficiency becomes deteriorated. A position of the tool when the tool is stopped is different from a position thereof when the tool is rotating. Hence, such an on-machine and non-contact measurement technique has been desired that measures the tool while the tool is kept rotating at a high speed.
An object of the present invention is to establish a technique to directly measure a gap between a tool in a rotating state and a workpiece.
In order to realize direct measurement of the gap between the tip end of the cut-lip of the tool and the workpiece, the present invention utilizes an edge of the workpiece, so as to acquire the length of the gap between the tip end of the tool rotating at a high speed (150000 rpm, for example) and the workpiece.
A method for measuring a length of a gap between a rotating tool and a workpiece using a laser beam according to the present invention includes generating a pulsed laser beam having a width greater than the gap between the rotating tool and the workpiece oppositely disposed to the rotating tool, and irradiating the gap with the generated pulsed laser beam whose optical axis is tilted relative to a plane of the workpiece. The pulsed laser beam has an oscillation pulse period that is one pulse per revolution or per an integer number of revolutions of the rotating tool, and is emitted in an identical angle range of the rotating tool during oscillation pulse ON durations. A light which is irradiated toward the gap and which is diffracted through the gap without being interrupted is detected on a light-receiving sensor, so as to measure a length of the gap.
A system for measuring a length of a gap between a rotating tool and a workpiece using a laser beam according to the present invention includes a laser source for generating a laser beam having a width greater than the gap between the rotating tool and the workpiece oppositely disposed to the rotating tool, and irradiating the gap with the generated laser beam whose optical axis is tilted relative to a plane of the workpiece, a controller for pulsing the laser beam to have an oscillation pulse period that is one pulse per revolution or per an integer number of revolutions of the rotating tool, so as to emit the pulsed laser beam in an identical angle range of the rotating tool during oscillation pulse ON durations, and a light receiving system for detecting on a light receiving sensor a light which is irradiated toward the gap and which is diffracted through the gap without being interrupted, so as to measure a length of the gap.
The light receiving sensor receives the pulsed laser beam emitted for a predetermined number of the periods, and detects an integrated diffracted light pattern during the predetermined number of the periods. The controller includes a laser oscillation pulse generating circuit for allowing a pulse phase adjustment of the laser beam, so as to generate the adjusted laser beam from the laser source, a motor-drive control circuit for rotating a motor for rotating the rotating tool synchronizedly with the laser oscillation pulse; and an electronic control shutter circuit for generating an ON-pulse signal equivalent to the pulsed laser beam for the predetermined number of the periods, so as to acquire a light receiving signal from the light-receiving sensor. The following condition is satisfied: an angle of diffraction θ+arcsin(λ/x)>a tilt angle of an optical axis ω>the angle of diffraction θ, where β represents a coefficient of a diffraction order light, λ represents a wavelength, x represents the length of the gap, and the angle of diffraction θ=arcsin(βλ/x).
The present invention realizes, in an ultra-precision machining center, a measurement of a length of a gap between a workpiece and a position of a tip end of a tool that is a high-speed rotating object rotating at hundreds of thousands of revolutions per minute with sub-micron accuracy. In the present invention, without using a reference knife-edge for conventionally use in the gap measurement method utilizing light diffraction, the gap between the tip end of the tool and the workpiece can be directly measured by using an edge of the workpiece as the reference edge with high accuracy. In addition, a laser beam is pulsed, thereby carrying out the measurement at a particular angular position of the tip end of the rotating tool.
The present invention will now be described with reference to illustrated examples.
In this manner, the laser beam is slantingly emitted from a semiconductor laser source, so that the diffracted light from the fine gap is acquired on the light receiving system (camera on the measurement unit). As explained with reference to
In the present invention, an edge of the workpiece is used instead of using the conventional reference knife-edge. In order to receive the diffraction pattern diffracted from the fine gap x, the following condition should be satisfied: a tilt angle of the optical axis ω>an angle of diffraction θ(=arcsin (βλ/x)). The upper limit of co is defined to be “θ+arcsin(λ/x)” (angle of arcsin(λ/x) is equivalent to an angle of a “next-order diffraction light”). The reason for this is because a further tilt results in picking up a diffraction order light signal having a greater noise level. β is a coefficient of the diffraction order light. Now, ω(>θ) is defined to be 15°, for example. In order to pick up the first-order diffracted light to third-order diffracted light (β=3.471) whose intensity is 20% of that of the first-order diffracted light using a laser beam of λ=650 nm, for example, the angle of diffraction θ is 13° if the fine gap x is 10 microns.
In the present invention, the oscillated laser beam is pulsed at a high speed.
As shown in the upper part of
As shown in the middle part of the
As shown in the lower part of
The clock signal having a predetermined clock frequency is used for controlling through the motor-drive control circuit a motor for rotating the rotating tool so as to rotate synchronizedly with the laser oscillation pulse. Instead of providing the motor-drive control circuit, a rotational speed (rotational position) detector of the rotating tool may be provided so as to control the clock signal frequency based on an output signal from this detector, thereby synchronizing the oscillation pulse of the laser beam with the rotation of the rotating tool. If the rotating tool is rotating at a high speed at a constant frequency, the irradiated position may be controlled by simply shifting the phase of the laser pulse. The clock signal is led to the electronic control shutter circuit, so as to generate an ON-pulse signal equivalent to the laser pulses for ten times, for example, so as to receive the light receiving signal from the light-receiving sensor, as described above.
In this manner, a particular position in the range of 360° of the rotating tool that is rotating at a high speed can be irradiated with the pulsed laser beam. In addition to this, the phase is adjusted by the phase control circuit shown in the drawing so as to shift the timing of the oscillation pulse of the laser beam, thereby irradiating the target irradiated position with the laser beam, or changing this target irradiated position. For example, if the oscillation timing is shifted by 0.5 μsec (3.6 degrees in terms of the angle) every time the measurement is carried out, the target position can be shifted in the angular direction.
One example of the specification of the measurement device is as follow. This measurement device includes a laser source, a reference edge adjusting unit, a Fourier transformer lens (diffracted light acquiring focal distance f=75 mm), and a CMOS camera (1 pixel=3.2 microns). A laser beam irradiating unit includes a semiconductor laser source (λ=635 nm, beam width: approximately 18 microns). The fine gap between the tool rotating at a high speed and the workpiece is slantingly irradiated with the line laser beam, thereby measuring the length of the gap between the edge of the workpiece and the tip end of the tool while the workpiece and the rotating tool are mounted on the machine.
Although only some exemplary embodiments of this invention have been described in detail above, those skilled in the art will readily appreciate that many modifications are possible in the exemplary embodiments without materially departing from the novel teachings and advantages of this invention. Accordingly, all such modifications are intended to be included within the scope of this invention.
Number | Date | Country | Kind |
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2010-170670 | Jul 2010 | JP | national |
Filing Document | Filing Date | Country | Kind | 371c Date |
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PCT/JP2011/064410 | 6/23/2011 | WO | 00 | 1/25/2013 |
Publishing Document | Publishing Date | Country | Kind |
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WO2012/014609 | 2/2/2012 | WO | A |
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