KR100952619B1 - The method of defecting badness for dealing a machine - Google Patents

Abstract

The present invention provides a method of detecting a failure in handling a machine tool which detects a process miss due to a material miss, tool wear and damage and a machine program error in real time during machining without indirect cycle time. Connect the terminal of the sensor processor (KH-30) and the three phases (u, v, w) of the machine tool servo shaft using a communication cable to detect KH-10), and the current sensor Connecting to another terminal of the sensor processor KH-30 for logarithmic operation using KH-20) and the u phase among three phases (u, v, w) of the machine tool servo shaft; Using the M-code signal interface of the machine tool together with the overall machining and tool number identification (KH130: start, KH140: end), the alarm signal generated from the monitoring program, the warning light and the machine stop signal (Feed hold, KH-60) Connecting; Setting up communication with a machine tool using the monitoring program, and repeating the above communication setting when there are a plurality of machine tools; In order to obtain the power value for the machining using the machine tool as a setting value (reference value, KH100), at least three materials are tested and processed, and when the value is normal, the machine tool is continuously used and the power value is maintained. Stopping use of the machine tool when it is outside the range of the limit line consisting of the upper limit line KH110, the lower limit line, and the essential passage line KH120; Testing whether the setting of the limit line is operating correctly; Monitoring the machine tool for proper operation; Automatically storing and confirming graph data related to the operation of the machine tool by tool, machine, date, and time; By proceeding in sequence, it is possible to prevent a large amount of defects that are prevented or missed in advance, and to effectively manage tool life, thereby increasing the maximum production rate.

Monitoring, material failure, tool wear, tool breakage, current sensor, sensor processor, real time, M-code

Description

Defect detection method when handling machine tools {THE METHOD OF DEFECTING BADNESS FOR DEALING A MACHINE}

The present invention relates to a method for detecting defects in the handling of machine tools generated by a machining program between a tool and a material during machining of all machine tools having numerical control (Numeric Control). In-process between tool and material through data acquired through sensor processor (KH-30) that checks current sensor (KH-20) and drive voltage (KH-10) on the servo shaft The present invention relates to an invention capable of identifying an effective processing load KH100.
Through such a function, real-time detection of process misses due to missing materials, tool wear and breakage and machine program errors can be detected and connected to a computer system as shown in FIG. It is about a method.

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In general, the production situation between the tool and the material of the machine tool is rampant with the following problems.

After processing by the user, the product can be visually checked or only through frequent and total inspection. Tool life is different depending on the skill of mounting the tool on the tool post according to the skill of the user.

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In addition, it is determined whether the user should touch the tool's condition directly during operation to set the tool's life consistently regardless of the condition of the materials and tools supplied through the company. Most of them are subject to some cycle time interference in the post-process and ambiguous management of tool costs for machining between user and manager (user governance).
In addition, the conventional method for detecting the state occurring between the tool and the workpiece of the machine tool is divided into four types as follows. However, in the field, there are problems in terms of performance and function to operate.

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First, it detects the maximum motor load of the machine through test operation using the attached load meter or machine current by using the CNC controller of some machine tools, and breaks the tool under conditions where the current load is greater than the maximum load during normal machining. It has been consistent with how to stop the equipment. However, the disadvantage of this method is that even though the load due to the actual machining does not reflect the processing voltage of the main shaft or the servo shaft, the detection sensitivity is remarkably weak, resulting in a large tool breakdown (drill only, no insert type applicable). May be possible, but it is disadvantageous in that the detection is poor in the case of bad mounting of the material or in the phenomenon of the tool wear. In addition, although the tool may be partially chipped or damaged during the actual machining, the overload may occur. However, if the tool is severely damaged, it may be impossible to detect if the spindle motor and the servomotor have no load despite the machining.

Secondly, when machining by tool is started, the detection range is displayed not only to monitor the detection range by the machining load but also to the idle and feed sections, which should not be detected unnecessarily, due to the machine tool PLC DATA operating system. Is the point.

Third, a tool-specific stop function is possible, but the tool-specific stop type cannot be selected. Due to the processing characteristics, such as a bad mounting of the material, if the machine tool is not immediately erected before processing, the headstock may crash, or the tool and the caster may be damaged at the same time as the problem of the tool. In addition, if the machine tool is immediately set up by overload detection during machining, the tool may dig into the workpiece, and it may be made defective even though it can be made good by reworking and correcting. The conventional stop type does not have the function of stopping immediately before the next tool is entered and after machining is completed, in addition to the function of immediately standing up when a problem occurs.

  Fourth, the load meter of the machine is significantly lower than the direct current sensor method (response time: 1.5, or more, minimum detection requirement (test after conclusion): 3㎲ or more), and offset shift ( % / ° C minimum requirement: ± 0.5).

Therefore, by using a sensor, which is a scientific and objective method to solve these problems, it is necessary to accurately detect the phenomenon occurring between the tool and the material during machining. In addition to being able to be set up, the user should be able to set up the detection functions easily and at the same time be able to select the stop types due to the nature of the process, and provide a way for the operator to quickly identify the problem tool number. The purpose is to.

Accordingly, the present invention devised in view of the above problems relates to a method for detecting a defect generated between a tool and a material and a machining program during machining of all machine tools having a numerical control function. In detail, processing is performed through data acquired through the sensor processor (KH-30) which checks the current sensor (KH-20) and the processing voltage (KH-10) together with the main shaft of the machine tool or servo shaft (In- In the process, you can check the effective processing load generated between the tool and the material. Through such a function, real-time detection of process misses due to missing materials, tool wear and breakage and machine program errors can be detected and connected to the computer system (KH-70) to use a user-friendly monitoring program. How to do that.

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The present invention provides a method of detecting a failure in handling a machine tool which detects a process miss due to a material miss, tool wear and damage and a machine program error in real time during machining without indirect cycle time. Connect the terminal of the sensor processor (KH-30) and the three phases (u, v, w) of the machine tool servo shaft using a communication cable to detect KH-10), and the current sensor Connecting to another terminal of the sensor processor KH-30 for logarithmic operation using KH-20) and the u phase among three phases (u, v, w) of the machine tool servo shaft; Using the M-code signal interface of the machine tool together with the overall machining and tool number identification (KH130: start, KH140: end), the alarm signal generated from the monitoring program, the warning light and the machine stop signal (Feed hold, KH-60) Connecting; Setting up communication with a machine tool using the monitoring program, and repeating the above communication setting when there are a plurality of machine tools; In order to obtain the power value for the machining using the machine tool as a setting value (reference value, KH100), at least three materials are tested and processed, and when the value is normal, the machine tool is continuously used and the power value is maintained. Stopping use of the machine tool when it is outside the range of the limit line consisting of the upper limit line KH110, the lower limit line, and the essential passage line KH120; Testing whether the setting of the limit line is operating correctly; Monitoring the machine tool for proper operation; Automatically storing and confirming graph data related to the operation of the machine tool by tool, machine, date, and time; It is characterized by proceeding sequentially.

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The present invention, unlike the indirect detection method (eg, road meter, machine current) using a conventional CNC, the phenomenon that occurs between the tool and the material of the machine tool is more reliably detectable, as shown in Figure 2 and 3 machine tool spindle or servo axis By using a sensor processor that checks the current sensor and the process voltage together in three phases (u phase of uv w), processing is no longer performed in accordance with various types of machine stop types that are forced (feed fed) and messages (eg warning lights) in real time. By notifying the user which tool has a problem on a machine tool, the user can prevent defects in advance or prevent mass defects that are missed, and efficient tool life can be managed to increase the maximum production rate. can do.

Also, as shown in FIGS. 2 and 3, the power value obtained by checking the current sensor and the processing voltage together on the three phases of the machine tool or servo shaft (u phase of uv w) is visualized for easy identification by a user using a general monitor. By showing the set machining start (KH130) and end (KH140) for each tool using the M-code signal, it is possible to quickly recognize the production process in which the problem occurs. In addition, with the ability to check the processing status of the entire product, the problem of delivery of defective materials and tools can be objectified, and there is an advantage of tracking back the defect history. The monitoring program can centrally control the tool status of multiple machine tools.

Hereinafter, the present invention will be described in detail with reference to the accompanying drawings.
The failure detection method when handling a machine tool according to an embodiment of the present invention detects a process miss due to a chipping miss, tool wear and breakage and machine program error in real time during machining without indirect cycle time. In a failure detection method when handling a machine tool, a terminal of a sensor processor (KH-30) and a machine tool servo shaft three-phase (u, v, w) are used to detect a drive voltage (KH-10) using a communication cable. ), And among the other terminals of the sensor processor (KH-30) and the machine tool servo shaft three phases (u, v, w), which log operation using the current sensor (KH-20) to detect the drive current. connecting to u; Using the M-code signal interface of the machine tool together with the overall machining and tool number identification (KH130: start, KH140: end), the alarm signal generated from the monitoring program, the warning light and the machine stop signal (Feed hold, KH-60) Connecting; Setting up communication with a machine tool using the monitoring program, and repeating the above communication setting when there are a plurality of machine tools; In order to obtain the power value for the machining using the machine tool as a setting value (reference value, KH100), at least three materials are tested and processed, and when the value is normal, the machine tool is continuously used and the power value is maintained. Stopping use of the machine tool when it is outside the range of the limit line consisting of the upper limit line KH110, the lower limit line, and the essential passage line KH120; Testing whether the setting of the limit line is operating correctly; Monitoring the machine tool for proper operation; Automatically storing and confirming graph data related to the operation of the machine tool by tool, machine, date, and time; It is characterized by proceeding sequentially.

When the machine tools are to be detected simultaneously or by selection, the current sensor (KH-20) and the driving voltage (selected in the three phases (u phase of uv w) of the machine tool spindle or servo shaft) Connect the sensor processor (KH-30), which checks KH-10) together, to a channel controller (KH-40) for each machine tool through a separate communication cable.
In particular, unlike the current consumption method using current sensors, the drive voltage (KH-10) and current sensor (KH-20) of the main shaft and servo motor are calculated together and reflected in the power consumption. The logarithmic decay rate (log) is applied to detect the state of.
Through this, the present invention outputs a graph KH120 as shown in FIG. 5 on the monitoring program as a sensitive response to the slight change in power consumption due to tool wear.

After the state is made, as shown in Figures 2 and 4 by connecting a relay connected to the M-code of the machining program of the machine tool to use the overall processing signal and the tool number identification signal (KH-50) Connect to the mentioned channel controller (KH-40). In addition, a warning light and a stop signal (KH-60) for mechanical feed hold are additionally connected to the channel controller (KH-40).

Next, when the above-described electrical wiring work is completed, the user first executes the monitoring program using a computer and a monitor based on the monitoring program processor of FIG. 1, and automatically corresponds to the first category "environment setting". Select the sensor, enter the machine tool name for easy identification, and connect the channel controller (KH-40) wirelessly or by wire (KH-80) to set the communication port. If multiple machine tools are detected, repeat the above method.

Next, select the second category “Settings” to obtain at least three materials with the user's visual inspection and normal new tools to obtain the settings (reference values) for monitoring which should be stored in the monitoring program. Should be processed normally. After that, it is processed normally at the user's judgment, and if the processing value storage is determined to be correct, the setting is made. However, this part is very important. First of all, if the standard is set by the excessive or small amount of processing, the error range of the set value may be out of range.

In addition, at least three materials must be processed. The first one is to calculate the total machining, tool number recognition and machining time, and the second is to obtain the setting value (reference value). The number of machining set from the second time is automatically stored as the average value excluding the highest and lowest values from the monitoring program. When machining, the tool number is recognized and displayed on this screen from the second time.

Then, if the setting value is calculated and stored, the limit line (for the part KH100) to be detected as shown in FIG. Select the upper limit, the lower limit, and the required passing line, and select and save the machine stop type (immediately, after processing or after processing) due to the processing characteristics if the limit line is violated. It is a function that generates an alarm at the end of the limit setting. It is intended to prevent a process drop or to detect a tool break during machining.

After the process-specific settings are completed, the user can select the fourth category, "Test" or the fifth category, "Monitoring." The function of the test is monitoring without alarm. Using this function, the user can check whether the tool setting is done properly or view the individual or cumulative monitoring graph every time the machining tool is processed. The cumulative graph function indirectly recognizes the limit of tool life. Can be used to set limits.

If the user does not select the fourth category “test” and wants to monitor immediately after “process setting”, he can select the fifth category “monitoring” directly. In this category, a number appears in the identification window for each tool during machining, the monitoring function can be turned off during monitoring, and the alarms that have occurred can be checked and deleted. In addition, if the user wants to save and print the entire machining history, he can do the whole processing history or the selected process processing history, the whole tool or the selected tool only.

The last six categories, “Alarm History”, allows users to re-check the alarms that have been generated so far, by date, and save or print them in removable memory. If you look up the alarm history, you can guess the cause of the defect that has occurred so far. Alarm history is recorded in detail by machine, tool, date and time.
In the above, the failure detection method when handling the machine tool of the present invention has been described through a preferred embodiment, which is not intended to limit the technical scope of the present invention, but is intended to help the understanding of the invention.
Those skilled in the art without departing from the technical gist of the present invention can be variously modified or modified, as well as such changes or modifications are within the technical scope of the present invention in the interpretation of the claims. Can't say.

1 is a monitoring program processor flowchart according to the present invention.

  2 is a concept of a monitoring system according to the present invention.

  3 is a connection diagram of a sensor processor according to the present invention.

  4 is a block diagram of a channel processor according to the present invention;

  5 is an example of a limit line section setting method used in the present invention.

Claims (1)

In the failure detection method in the handling of machine tools, which detects the process miss due to the machining miss, tool wear and damage and machine program error in real time during machining without indirect cycle time, To detect the drive voltage (KH-10), connect the terminals of the sensor processor (KH-30) with the three-phase (u, v, w) of the machine tool using a communication cable, and detect the drive current. Connecting another terminal of the sensor processor KH-30 for logarithmic operation using the current sensor KH-20 and the u phase among three phases u, v, w of the machine tool servo shaft; Using the M-code signal interface of the machine tool together with the overall machining and tool number identification (KH130: start, KH140: end), the alarm signal generated from the monitoring program, the warning light and the machine stop signal (Feed hold, KH-60) Connecting; Setting up communication with a machine tool using the monitoring program, and repeating the above communication setting when there are a plurality of machine tools; In order to obtain the power value for the machining using the machine tool as a setting value (reference value, KH100), at least three materials are tested and processed, and when the value is normal, the machine tool is continuously used and the power value is maintained. Stopping use of the machine tool when it is outside the range of the limit line consisting of the upper limit line KH110, the lower limit line, and the essential passage line KH120; Testing whether the setting of the limit line is operating correctly; Monitoring the machine tool for proper operation; Automatically storing and confirming graph data related to the operation of the machine tool by tool, machine, date, and time; Defect detection method when handling a machine tool, characterized by proceeding sequentially

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