JP2004038565A - Monitoring device of machine tool - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a monitoring device of machine tool capable of monitoring the operation and state of a machine tool in real time and quickly specifying an abnormality occurrence position. <P>SOLUTION: This monitoring device 1 comprises a signal receiving means 11 for receiving a control signal 8 for operating actual equipment 2 and an operation response signal 9, which is connected to an operation control part 6 comprising the operation board 3 of the actual equipment 2, a PCL 4 and a CNC device 5 through a communication cable 7; a RAM 16 for storing mechanical element information 15; a virtual model creation means 18 for creating a virtual model 17 of the actual equipment 2 based on the mechanical element information 15; a virtual control means 19 for controlling the virtual model 17 based on the signals 8 and 9 to simulate the operation of the actual equipment 2 in real time; a display control means 20 and a CRT 21 for three-dimensionally displaying the virtual model 17; a color identification and output means 22 for identifying and outputting the state of each part of the actual equipment 2 by color; and a character information output means 23 for outputting the state of each part with character information. <P>COPYRIGHT: (C)2004,JPO

Description

[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a machine tool monitoring device, and more particularly, to a machine tool monitoring device capable of grasping the operating state of a machine tool in real time by a three-dimensionally displayed virtual model of the machine tool.
[0002]
[Prior art]
2. Description of the Related Art Conventionally, when performing work such as cutting and grinding of a work, a CNC device that numerically controls movements in X, Y, and Z-axis directions orthogonal to each other to control position of the work and the work tool, and operation of the work tool. 2. Description of the Related Art Machine tools having a PLC for controlling the sequence of operations and the like and capable of processing complicated shapes with high accuracy and high efficiency are widely used in various industrial fields.
[0003]
These machine tools are equipped with a column that stands vertically on a bed that serves as a base for the entire machine, a spindle head that includes a spindle connected to the column and rotates a machining tool, and the like. ATC that automatically installs and replaces main components including a table that is installed and fixed to support a workpiece (work), and a drive mechanism that moves the table, column, spindle, etc., straight or rotationally. (Automatic tool changer), APC (automatic pallet changer) that automatically changes pallets, coolant supply device that supplies coolant (cutting fluid) that removes heat, etc. generated during cutting, and chips after machining Chip processing device, a peripheral device consisting of a cover covering the entire machine tool, electrical equipment for driving each device, and hydraulic / pneumatic equipment, and a CNC device Often it is configured from a control unit such as a PLC · operation panel (control system).
[0004]
[Problems to be solved by the invention]
As described above, a machine tool is a combination of a plurality of machine parts, devices, electronic devices, and the like. Further, the work space of the work is surrounded by the above-described cover or the like in order to protect the work tool from rotating at a high speed and prevent coolant and chips from scattering. Therefore, during operation of the machine tool, it was difficult to directly check the movement of the processing tool and the work with the naked eye. Some machine tools have a small window on the cover for checking the state of the machining space.However, because of high-pressure injection of coolant and hiding behind the machining tool, etc. It was not possible to visually confirm the shape of the work.
[0005]
Furthermore, when an abnormality occurs during operation of the machine tool and a fail-safe system or the like functions, the machine tool is in an emergency stop state. Therefore, in order to identify the cause of the abnormality, it was necessary to open and confirm the cover. However, in such a situation, the cover could not be opened without going through various steps for safety confirmation. As a result, the cause of the abnormality is delayed, and appropriate measures cannot be taken promptly.
[0006]
Further, when an abnormality occurs in the NC axis, an operation of manually returning the NC axis to the origin may be performed by a manual pulse generator provided in the operation unit. At this time, an operation was performed to move each NC axis to the origin position while manually rotating the handle of the manual pulse generator. However, the field of view is obstructed by a cover, a work, or the like, and it is difficult to perform an operation while always checking the NC axis, and there is a high possibility that a processing tool or a machine tool may be damaged by an erroneous operation. Therefore, a device that can perform a return operation while visually recognizing the position and state of the NC axis and the like has been desired.
[0007]
Furthermore, as described above, the machine tool has a function of notifying an operator or the like of such abnormality when detecting any abnormality by a sensor or the like, and performing a measure such as an emergency stop. However, the means for informing the user of the abnormality is limited to displaying the buzzer or the location of the abnormality on the operation panel on the operation panel by flashing a lamp or the like, and there is no means for informing the operator of the location of the abnormality or the specific content of the abnormality. Was. In particular, in the case of an electrical trouble, it is necessary to identify the cause of the abnormality while verifying the ladder circuit incorporated in the PLC. However, the analysis and decoding of the ladder circuit must be entrusted to a specialist engineer, and the identification of the cause of the abnormality may be further delayed.
[0008]
In view of the above circumstances, an object of the present invention is to provide a machine tool monitoring device capable of monitoring an operation and a state of a machine tool in real time and capable of promptly specifying a location where an abnormality has occurred.
[0009]
[Means for Solving the Problems]
In order to solve the above problems, a monitoring device for a machine tool according to the invention of claim 1 is connected to a machine tool, and includes at least a control signal for controlling the machine tool and an operation response signal corresponding to the operation of the machine tool. Signal receiving means for receiving one of them, shape definition data defining the shape of each part constituting the machine tool, connection state data indicating the connection state of each part, and the operation of each part corresponding to the control signal Storage means for storing machine element information including operation data shown; virtual model construction means for constructing a virtual model of the machine tool based on the machine element information; and at least one of the received control signal and the operation response signal. Virtual control means for controlling the virtual model based on either one of the virtual models and simulating an operating state of the machine tool; Model in which and a display means for displaying in three-dimensional.
[0010]
Here, the signal receiving means is a control signal for controlling an actual machine tool (hereinafter, referred to as "actual machine"), and an operation response signal (corresponding to a feedback signal) output by a sensor such as a rotary encoder as a result of the control. Is what you receive. Thereby, the virtual model is controlled using the same signals as those of the real machine, and the operation of the machine tool is simulated.
[0011]
In addition, the machine element information stores various data for constructing a virtual model of a machine tool in a virtual space in a computer. Specifically, cylinders, valves, tables, servomotors, and NC shafts that constitute the machine tool are defined with shape definition data in which the shape and size are defined, and the connection or connection state of each unit is defined. Connection status data indicating the positional relationship and the subordination relationship of each part, operation modes (such as straight-ahead and rotation operations) and operation details (reference position, operation limit range, movement amount, operation speed, acceleration, rotation speed) of each part operation , And operation data defining an operation order based on the sequence control.
[0012]
Therefore, according to the machine tool monitoring device of the first aspect of the present invention, a virtual model of the machine tool is constructed based on the machine element information, and is displayed in three dimensions. Then, the virtual model is controlled by the control signal and the operation response signal transmitted from the real machine in the same manner as the operation of each part of the real machine. Thereby, the operator (= monitor) can visually grasp the operation of each unit of the real machine by the displayed virtual model. Here, it is also possible to control the virtual model using either the control signal or the operation response signal. That is, by using the control signal, the virtual model can be controlled in a state where the virtual model is separated from the actual machine, and application to operation training or the like of the actual machine becomes possible. On the other hand, by using the operation response signal, it is possible to faithfully reproduce based on the operation of the actual device. Then, by using both the control signal and the operation response signal, the operation of the actual machine can be reproduced more closely.
[0013]
A monitoring device for a machine tool according to a second aspect of the present invention is the monitoring device for a machine tool according to the first aspect, wherein the control signal includes a programmable logic controller for controlling the sequence of the machine tool and a numerical value for the machine tool. It is output from at least one of the numerical control devices to be controlled.
[0014]
Here, the PLC controls the operation of each part of the machine tool in sequence according to a sequence program stored in advance. On the other hand, the CNC device performs each control based on a numerical control program stored inside. This enables the position of the shaft to be controlled. The machine tool is controlled by control signals output from the PLC and the CNC device, and an operation response signal (corresponding to a feedback signal) corresponding to the operation is returned to the PLC. That is, signals for controlling the machine tool are concentrated on the PLC and the CNC device. Therefore, by connecting to these devices, a signal for causing the virtual model to simulate the operation of the machine tool can be received.
[0015]
Therefore, according to the machine tool monitoring device of the second aspect of the present invention, in addition to the function of the machine tool monitoring device of the first aspect of the present invention, a control signal transmitted from a PLC and a CNC device constituting a part of an actual machine is provided. Alternatively, the virtual model is controlled according to the operation response signal, and the operation of the real machine is simulated. Further, since the signal is transmitted at the same timing as the operation of the real machine, the operation between the virtual model and the real machine is synchronized. In other words, it is possible to display the operation of the real machine in real time using a virtual model. Further, since the monitoring device does not send a signal to a device such as a PLC, the processing on the actual device does not have a burden.
[0016]
A monitoring device for a machine tool according to a third aspect of the present invention is the monitoring device for a machine tool according to the first or second aspect, wherein the display unit identifies and outputs a state of each of the parts of the machine tool. It further comprises identification output means.
[0017]
Therefore, according to the machine tool monitoring device of the third aspect of the invention, in addition to the function of the machine tool monitoring device of the first or second aspect of the invention, the state of each part of the real machine is identified and output to the virtual model. Is done. In other words, in the control signal and the operation response signal of the actual device, in addition to the normal signal that causes the normal operation to be sequentially performed by the sequence control, a state in which an abnormality is reported or an abnormality is highly likely to occur. That indicate the state of the machine tool, such as those that notify the user in advance. Therefore, when such a signal is received, the state of each part of the machine tool is identified according to the signal, and the state is output so that the state can be visually displayed. For example, when each part of the actual machine is in normal operation status = "green", when it is likely that an abnormality will occur such as the time to change the machining tool is approaching = "yellow", or when the actual machine has an emergency stop, etc. Occurrence = “red” or the like is defined in advance, and the color for displaying each part of the virtual model is changed according to the state. This allows the operator to quickly recognize the state of each part of the machine tool.
[0018]
A monitoring device for a machine tool according to a fourth aspect of the present invention is the monitoring device for a machine tool according to any one of the first to third aspects, wherein the display means displays a state of each of the parts of the machine tool. It further comprises character information output means for outputting the character information shown.
[0019]
Therefore, according to the machine tool monitoring device of the fourth aspect of the present invention, in addition to the operation of the machine tool monitoring device of any one of the first to third aspects of the present invention, the state of each part constituting the machine tool can be changed. The indicated character information is output and displayed. For example, for example, "the wheel is rotating" indicating that the wheel is supporting the machining tool for grinding, and "the wheel is rotating" or a specific numerical value of the wheel speed "wheel speed = O, OOrpm" And so on, it is possible to supplement information that cannot be understood only by displaying the three-dimensional virtual model. Further, when an abnormality occurs, an abnormal location can be displayed, and a specific state and content can be displayed.
[0020]
BEST MODE FOR CARRYING OUT THE INVENTION
Next, a machine tool monitoring device (hereinafter, referred to as a “monitoring device 1”) according to an embodiment of the present invention will be described with reference to FIGS. Here, FIG. 1 is a schematic configuration diagram showing a configuration of a monitoring device connected to an actual device, FIG. 2 is a block diagram showing a functional configuration of the monitoring device 1, and FIG. 3 is a schematic display example of a virtual model screen. FIG. 4 is an explanatory diagram schematically showing an example of abnormality notification using a virtual model. Here, in the present embodiment, an example of a grinding machine, particularly a cylindrical grinding machine, will be described as a machine tool.
[0021]
As shown in FIG. 1, the monitoring device 1 of the present embodiment is connected via a communication cable 7 to an operation control unit 6 including an operation panel 3, a PLC 4, and a CNC device 5, which constitute a part of the actual device 2. . Further, as a functional configuration of the monitoring device 1, as shown in FIG. 2, a signal receiving unit that receives, via an IF (interface) 10, a control signal 8 and an operation response signal 9 transmitted and received when controlling the actual device 2. 11, shape definition data 12 defining the shape and size of each unit constituting the actual machine 2, connection state data 13 indicating the connection and connection state of each unit, and operation data 14 defining the operation content of each unit and the like. RAM 16 for storing machine element information 15, virtual model construction means 18 for constructing virtual model 17 of real machine 2 based on stored machine element information 15, control signal 8 for receiving virtual model 17 by signal reception means 11, A virtual control means 19 for controlling based on the operation response signal 9 to simulate the operation of the real machine 2 in real time; A display control means 20 and a CRT 21 for displaying the three-dimensional image 17 in a three-dimensional form; a color identification output means 22 for outputting the normal or abnormal state of each part of the actual machine 2 for each color; It is composed of character information output means 23 for outputting information 41 and supplementing the state.
[0022]
Here, the signal receiving unit 11, the virtual model construction unit 18, the virtual control unit 19, the color identification output unit 22, and the character information output unit 23 are part of the functions of the CPU 24 that performs various arithmetic processes in the monitoring device 1. It's being used. Further, the RAM 16 corresponds to the storage unit in the present invention, and the color identification output unit 22 corresponds to the identification output unit in the present invention.
[0023]
Further, the monitoring device 1 includes an operating system (OS) 25 that enables basic operation of the entire device, and a color identification output unit for displaying the virtual model 17 displayed in a three-dimensional form according to the color of the real device 2. ROM 28 which stores color identification data 26 used by 22 and character information data 27 for outputting character information 41 by character information output means 23, and keyboard 29 for performing various operations and inputs in monitoring device 1. And a mouse 30.
[0024]
Here, the monitoring device 1 of the present embodiment can use hardware such as a commercially available personal computer. Further, in addition to the RAM 16, a drive device capable of reading a fixed storage medium such as a hard disk or a portable storage medium such as a flexible disk or a compact disk may be provided as storage means.
[0025]
Next, an example of monitoring the operating status of the actual machine 2 using the monitoring device 1 of the present embodiment will be described with reference to FIGS. First, as shown in FIG. 1, the monitoring device 1 is connected to the operation control unit 6 of the actual device 2 via the communication cable 7. Then, on the CRT 21 of the monitoring device 1, a virtual model 17 of the connected real machine 2 is constructed by the virtual model construction means 18 based on the machine element information 15 stored in the RAM 16, and is displayed three-dimensionally ( (See FIG. 3).
[0026]
Here, FIG. 3 schematically shows the vicinity of a processing space including a processing tool, a workpiece, and the like in the virtual model 17 of the constructed real machine 2. More specifically, FIG. 3 shows a wheel 31 as a working tool for grinding, a wheel base 33 that horizontally supports a wheel shaft 32 to which the wheel 31 is attached, and a wheel base 33. The mounted X-axis table 34a, a servomotor 35a for numerically controlling the X-axis table 34a to move in the X-axis direction (see FIG. 3), and a rotatable arrangement between the headstock 36 and the tailstock 37. Numerical control is performed on the work 38, a shake stopper 39 for stopping the work 38 from oscillating, a headstock 36, a tailstock 37, and a Z-axis table 34 b on which the shake stopper 39 is mounted. The servo motor 35b that moves in the Z-axis direction (see FIG. 3) is virtually drawn as the virtual model 17. Here, the actual processing space is covered by a cover 40 or the like so that it cannot be visually confirmed. However, in the monitoring device 1 of the present embodiment, image processing for removing the cover 40 is performed, and the visibility of the processing space is improved. Is displayed.
[0027]
Thereafter, a control signal 8 for numerically controlling each NC axis and for sequence controlling the operation of each unit is sent from the operation control unit 6 of the actual machine 2, and each unit of the actual machine 2 operates based on a preset program. . Then, the operation response signal 9 corresponding to the operation is fed back to the PLC 4 or the like, and a command such as the timing of starting the operation of the next step is issued. At this time, the monitoring device 1 controls the actual device 2 from the operation control unit 6, and receives individual signals 8 and 9 based on the control via the communication cable 7. Then, the constructed virtual model 17 is controlled using the received control signal 8 and operation response signal 9. At this time, since the signals 8 and 9 are transmitted at the same timing as the real machine 2, the operation of each unit of the real machine 2 and the control of each unit (virtual) of the virtual model 17 are performed simultaneously. Therefore, the operation of the real machine 2 is reproduced by the virtual model 17 in real time.
[0028]
Then, the reproduced state of the control (simulation of the operation) of the virtual model 17 is three-dimensionally displayed on the CRT 21. Thereby, the operator of the monitoring device 1 can recognize the movement of the real device 2 through the virtual model 17 in real time. In addition, since the monitoring device 1 of this embodiment is constructed virtually, each part to be displayed is appropriately selected and displayed, or the entire virtual model 17 is rotated to rotate the virtual model 17 from any direction of 360 degrees. The display can be changed so that it is easy for the operator to see by using a well-known image processing technique (details are omitted) such as making it possible to confirm or to enlarge or reduce only the operation part. For this reason, the processing operation that was conventionally covered with the cover of the actual machine 2 and was unable to see the shape or the like of the work being processed can be visually confirmed using the virtual model 17. Further, the work can be performed while checking the shape of each step of the work.
[0029]
In addition, on the display screen of the CRT 21, character information 41 indicating the state of each main part of the virtual model 17 is displayed. As shown in FIG. 3, for example, the state of each part, the current position of each part, and the like are displayed by characters, such as “while the wheel is rotating” 41 and “open end 1 of the door” 41. Therefore, by looking at the displayed virtual model 17, the operator can grasp the operation and the positional relationship of each part of the real machine 2 and recognize the state of the real machine 2 by characters. Note that the character information 41 can display character and numeral information such as a set numerical value, a current numerical value, and the actual rotation speed of the spindle.
[0030]
Further, as shown in FIG. 4, the monitoring device 1 of the present embodiment can identify and display the status of each unit of the real machine 2 for each abnormal level such as normal, caution, and abnormal. For example, “normal” = green (indicated by a solid line in FIG. 4), “caution” = yellow (indicated by a two-dot chain line in FIG. 4), and “abnormal” = red (indicated by a broken line in FIG. 4). be able to. Thus, the operator can quickly recognize the state of the actual machine 2 by the color. In addition, each part of the virtual model 17 can be identified and displayed for each color, and its abnormal state or caution can be displayed in association with the character information 41 described above. For example, in FIG. 4, “!! Abnormal rotation speed of wheel shaft!” 41a, “NC (X axis) error!” 41b, “NC (Z axis) error!” 41c, “! "Time!" 41d.
[0031]
As a result, the occurrence of an abnormality related to the actual machine 2 and a display for alerting are performed to the operator. Can be taken. In the case where the actual machine 2 is emergency-stopped due to an abnormality and it is necessary to take immediate action against the abnormality, the display portion of the character information 41 is blinked on the display screen of the CRT 21 or an alarm is issued by sound or the like. May be further provided.
[0032]
As described above, the monitoring device 1 of the present embodiment controls the virtual model 17 that is virtually constructed using the actual control signal 8 and the operation response signal 9 that are transmitted when the real device 2 is operated. However, the operation of the actual machine 2 can be simulated in real time. Accordingly, since the virtual model 17 reproduces exactly the same operation as that of the real machine 2, it is difficult for the operator to directly check with the naked eye the operation of each part of the real machine 2, which is visually dangerous through the display of the three-dimensional virtual model 17. Can be recognized without gender.
[0033]
Further, even when an error occurs in the NC axis and the operation of returning to the home position by a manual pulse generator (not shown), what has been performed while looking at the NC axis of the actual machine 2 is displayed on the monitoring device 1. The return operation can be performed while confirming the position and the movement amount of the NC axis of the real machine 2 using the virtual NC axis (not shown) of the virtual model 17. Thereby, unlike the related art, the possibility that the working tool or the actual machine 2 is damaged is reduced.
[0034]
Further, the monitoring device 1 of the present embodiment can display the state of each part by identifying the state by color, and further display the state of each part supplemented by the character information 41. As a result, the operator can quickly identify the location where the abnormality has occurred and recognize the state of the abnormality / caution. Therefore, it does not require much time to analyze the ladder circuit as in the case of specifying the cause of the abnormality in the related art. Therefore, the cause of the abnormality is specified promptly, and the response and the return work are facilitated. Therefore, it is possible to reduce the influence on the production line due to the failure of the machine tool, and to prevent a decrease in production efficiency.
[0035]
As described above, the present invention has been described with reference to the preferred embodiments. However, the present invention is not limited to these embodiments, and various improvements can be made without departing from the gist of the present invention as described below. And design changes are possible.
[0036]
That is, in the monitoring apparatus 1 of the present embodiment, the operating state of the actual machine 2 is indicated in three stages of normal, caution, and abnormality, and is identified and displayed by three colors (green, yellow, and red). The present invention is not limited to this, and the state identification may be displayed in multiple stages. Further, the colors used for display are of course not limited to these.
[0037]
【The invention's effect】
As described above, the machine tool monitoring device according to the first aspect of the present invention can reproduce the operation of the operating machine tool in a virtual model in real time. As a result, it is possible to confirm on the screen even a portion that was conventionally difficult to visually confirm. Thus, the operation of each part of the machine tool can be safely confirmed even during operation.
[0038]
The monitoring device for a machine tool according to the second aspect of the present invention provides a virtual machine utilizing control signals from a PLC and a CNC device for actually controlling the machine tool in addition to the effects of the monitoring device for a machine tool according to the first aspect of the invention. The model is controlled. Therefore, since the virtual model is controlled by the signal transmitted at the same timing as the operation of the machine tool, the operation of the virtual model is simulated in real time. Further, since no signal is sent from the monitoring device to the machine tool, no processing load is applied to the machine tool, and the operation of the machine tool is not affected.
[0039]
According to a third aspect of the present invention, in addition to the effects of the first and second aspects of the present invention, the machine tool monitoring device displays the state of each part of the machine tool in addition to the operation of the machine tool. Can be. As a result, it is possible to quickly identify the location where the abnormality has occurred and to grasp the abnormal state, and to appropriately deal with the abnormality and perform a recovery operation.
[0040]
According to the fourth aspect of the present invention, in addition to the effects of the first and second aspects of the invention, the state of each part of the machine tool can be output as character information. This makes it easier to grasp the state of each part.
[Brief description of the drawings]
FIG. 1 is a schematic configuration diagram showing a configuration of a monitoring device connected to an actual device.
FIG. 2 is a block diagram showing a functional configuration of the monitoring device.
FIG. 3 is an explanatory diagram schematically showing a screen display example of a virtual model.
FIG. 4 is an explanatory diagram schematically showing an example of abnormality notification using a virtual model.
[Explanation of symbols]
1 monitoring equipment (monitoring equipment for machine tools)
2 Actual machine (machine tool)
4 PLC (Programmable Logic Controller)
5 CNC device (numerical control device)
8 control signal 9 operation response signal 11 signal receiving means 12 shape definition data 13 connection state data 14 operation data 15 machine element information 16 RAM (storage means)
17 virtual model 18 virtual model construction means 19 virtual control means 20 display control means (display means)
21 CRT (display means)
22 Color identification output means (identification output means)
23 character information output means 41 character information

Claims (4)

Connected to a machine tool, a signal receiving means for receiving at least one of a control signal for controlling the machine tool and an operation response signal corresponding to the operation of the machine tool,
Stores machine element information including shape definition data defining the shape of each part constituting the machine tool, connection state data indicating a connection state of each part, and operation data indicating operation of each part corresponding to the control signal. Storage means;
Virtual model construction means for constructing a virtual model of the machine tool based on the machine element information,
Virtual control means for controlling the virtual model based on at least one of the received control signal and the operation response signal, and simulating an operation state of the machine tool,
Display means for displaying the controlled virtual model in three dimensions and displaying the virtual model. The control signal is
The machine tool monitoring device according to claim 1, wherein the output is output from at least one of a programmable logic controller that performs sequence control of the machine tool and a numerical controller that numerically controls the machine tool. The display means,
The monitoring device for a machine tool according to claim 1, further comprising an identification output unit configured to identify and output a state of each unit of the machine tool. The display means,
The machine tool monitoring device according to claim 1, further comprising a character information output unit that outputs character information indicating a state of each section of the machine tool.

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