CN110877233A - Wear loss estimation system, wear loss estimation method, correction system, abnormality detection system, and life detection system - Google Patents
Wear loss estimation system, wear loss estimation method, correction system, abnormality detection system, and life detection system Download PDFInfo
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- CN110877233A CN110877233A CN201910831733.2A CN201910831733A CN110877233A CN 110877233 A CN110877233 A CN 110877233A CN 201910831733 A CN201910831733 A CN 201910831733A CN 110877233 A CN110877233 A CN 110877233A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23Q—DETAILS, COMPONENTS, OR ACCESSORIES FOR MACHINE TOOLS, e.g. ARRANGEMENTS FOR COPYING OR CONTROLLING; MACHINE TOOLS IN GENERAL CHARACTERISED BY THE CONSTRUCTION OF PARTICULAR DETAILS OR COMPONENTS; COMBINATIONS OR ASSOCIATIONS OF METAL-WORKING MACHINES, NOT DIRECTED TO A PARTICULAR RESULT
- B23Q17/00—Arrangements for observing, indicating or measuring on machine tools
- B23Q17/09—Arrangements for observing, indicating or measuring on machine tools for indicating or measuring cutting pressure or for determining cutting-tool condition, e.g. cutting ability, load on tool
- B23Q17/0952—Arrangements for observing, indicating or measuring on machine tools for indicating or measuring cutting pressure or for determining cutting-tool condition, e.g. cutting ability, load on tool during machining
- B23Q17/0957—Detection of tool breakage
Abstract
The invention provides a wear amount estimation system, a wear amount estimation method, a correction system, and an abnormality/life detection system, which can improve the accuracy of the estimated wear amount of a tool. The wear amount estimation system of the present invention includes: a storage unit that stores a linear transformation P as follows: setting the wear amount of the tool from the machining start time point as W, the elapsed time as t, and the constant as A1、A2、α1、α2A linear transformation from formula 1 to formula 2, wherein formula 1 is W ═ a1tα1(t≤T0) Wherein formula 2 is W ═ A2tα2(T0< t); a calculation unit that calculates equation 1 for tools in machining of the same specification; and an estimating unit that reads out the data from the storage unitThe linear transformation P estimates expression 2 obtained by linearly transforming expression 1 calculated by the calculation unit as expression 2 of the tool being machined.
Description
Technical Field
The invention relates to a wear amount estimation system, a calibration system, an abnormality detection system, a life detection system, a machine tool, and a wear amount estimation method.
Background
There is known a machine tool that uses a tool to correct the wear amount of the tool for a workpiece of the same specification and repeatedly performs machining under the same conditions. Such a machine tool is disclosed in, for example, japanese patent application laid-open No. 8-132332 (patent document 1).
Documents of the prior art
Patent document
Patent document 1: japanese laid-open patent publication No. 8-132332
Disclosure of Invention
Problems to be solved by the invention
Means for solving the problems
The purpose of the present invention is to improve the accuracy of estimated wear amount of a tool.
A wear amount estimation system according to a 1 st aspect of the present invention is a wear amount estimation system for estimating a wear amount of a tool in a machine tool that repeatedly machines a workpiece of the same specification using the tool under the same conditions, the wear amount estimation system including: a storage unit for storing a linear transformation P in which W is an amount of wear of a tool from a machining start time point, t is an elapsed time, and A is a constant1、A2、α1、α2A linear transformation from formula 1 to formula 2, wherein formula 1 is W ═ a1tα1Wherein T is less than or equal to T0Wherein formula 2 is W ═ A2tα2Wherein T is0T; a calculation unit that calculates the formula 1 for the tools in machining of the same specification; and an estimating unit that reads out the linear transformation P from the storage unit and estimates expression 2 obtained by performing linear transformation on expression 1 calculated by the calculating unit as expression 2 of the tool being machined.
In accordance with the wear amount estimation method according to the 2 nd aspect of the present invention, there is provided a wear amount estimation method for estimating a wear amount of a tool in a machine tool that repeatedly machines a workpiece of the same specification using the tool under the same conditions, the wear amount estimation method including: a step of preparing a storage unit for storing a linear transformation P in which a wear amount of a tool from a machining start time point is W, an elapsed time is t, and a constant is A1、A2、α1、α2A linear transformation from formula 1 to formula 2, wherein formula 1 is W ═ a1tα1Wherein T is less than or equal to T0Wherein formula 2 is W ═ A2tα2Wherein T is0T; calculating the formula 1 for the cutting tools with the same specification in the processing process; and a step of reading out the linear transformation P from the storage unit, and estimating expression 2 obtained by performing linear transformation from the calculated expression 1 as expression 2 of the tool being machined.
Effects of the invention
As described above, the present invention can provide a wear amount estimation system, a correction system, an abnormality detection system, a life detection system, a machine tool, and a wear amount estimation method that improve the accuracy of an estimated wear amount of a tool.
Drawings
Fig. 1 is a schematic view of a machine tool in an embodiment.
Fig. 2 is a graph showing the amount of wear of the tool with respect to elapsed time in the embodiment.
Fig. 3 is a block diagram showing a control structure of a machine tool in the embodiment.
Fig. 4 is a diagram for explaining a method of estimating expression 2 from expression 1 in the embodiment.
Fig. 5 is a flowchart illustrating a wear amount estimation method in the embodiment.
Fig. 6 is a flowchart illustrating a correction method in the embodiment.
Fig. 7 is a diagram showing a relationship determined in the wear amount estimation system in the embodiment and a measured value of the tool in operation.
Fig. 8 is a diagram for explaining parameters of an error index in the embodiment.
Fig. 9 is a diagram for explaining an error index in the embodiment.
Fig. 10 is a diagram for explaining another error index in the embodiment.
Fig. 11 is a diagram for explaining another error index in the embodiment.
Fig. 12 is a flowchart illustrating an abnormality detection method in the embodiment.
Fig. 13 is a flowchart illustrating a lifetime detection method in the embodiment.
Fig. 14 is a graph showing the wear amount of the cutter in the embodiment.
Fig. 15 is a diagram in which normal data is extracted in fig. 14.
Fig. 16 is a graph showing the amount of wear of the tool with respect to elapsed time in the embodiment.
FIG. 17 is a log in the illustrated embodiment10A1、log10A2And α1A diagram of a three-dimensional map of (2).
FIG. 18 is a log in the illustrated embodiment10A1、α1And α2A diagram of a three-dimensional map of (2).
Fig. 19 is a diagram showing measured values and estimated values in the embodiment.
Description of the symbols
1: machine tool
2: cutting tool
3: support part
4: placing part
5: workpiece to be processed
10: wear amount estimation system
11: storage unit
12: measuring part
13: calculating part
14: estimation unit
20: correction system
21: correcting part
30: abnormality detection system
31: abnormality determination unit
32: abnormality display unit
40: life detection system
41: life determining part
42: service life display unit
43: notification part
Detailed Description
Hereinafter, embodiments of the present invention will be described with reference to the drawings. In the following drawings, the same or corresponding portions are denoted by the same reference numerals, and description thereof will not be repeated.
A wear amount estimation system, a correction system, an abnormality detection system, a life detection system, a machine tool, and a wear amount estimation method according to an embodiment of the present invention will be described with reference to fig. 1 to 13.
(machine tool)
As shown in fig. 1, a machine tool 1 repeatedly machines workpieces 5 of the same specification under the same conditions using a tool 2. This enables the workpiece to be machined into a machined product having the same shape.
The term "workpieces of the same specification" refers to workpieces produced under the same conditions. The material of the workpiece is not particularly limited, and may be a metal or a material other than a metal. "repeatedly machining under the same conditions" means that the plurality of workpieces are machined under the same conditions so that the workpieces have the same shape.
The machine tool 1 includes a tool 2, a support portion 3, and a placement portion 4. The tool 2 machines a workpiece 5. The method of machining is not particularly limited, and examples thereof include cutting. The support portion 3 supports the cutter 2. The support portion 3 is movable in the left-right (x-axis) direction, the front-back (y-axis) direction, and the up-down (z-axis) direction. The position of the tool 2 can be moved by the movement of the support portion 3. The mounting unit 4 mounts the workpiece 5 thereon. The support portion 3 moves relative to the workpiece 5 placed on the placement portion 4. Therefore, the placement unit 4 can also move in the left-right direction, the front-back direction, and the up-down direction.
The machine tool 1 is an nc (numerical control) machine tool, and further includes a numerical controller that controls the operation of the machine tool 1. The control device instructs the tool 2 for a process of a work necessary for machining, such as a path to a workpiece, using corresponding numerical information.
When the operation of the machine tool 1 is continued, the tool 2 is worn out because the workpiece 5 is machined by the tool 2. Further, the tool 2 is worn or damaged during the operation of the machine tool 1. In this way, when the workpiece having the same shape cannot be machined, the other tool 2 having the same specification is replaced. "tools of the same specification" means tools manufactured under the same conditions.
(wear amount estimating System)
< amount of wear with respect to elapsed time >
First, the relational expression will be described with reference to fig. 2. The wear amount W of the tool 2 with respect to the elapsed time t from the machining start time point can be represented by a model shown in fig. 2. The wear period of the tool with respect to the elapsed time from the machining start time point is: an abrasion loss of W1The following initial stage (t is more than 0 and less than or equal to t)0) The amount of wear exceeds W1And W2The following stabilization phase (t)0＜t≤t1) And the amount of wear exceeds W2Last phase of (t)1< t). The initial stage is a state in which the wear amount changes greatly. The stable phase is a state in which the wear amount change is small and stable. The final stage is a state in which the wear amount rapidly increases and the life is reached.
At the initial stage and the stable stage (t is more than 0 and less than or equal to t) of the tool 2 until the tool reaches the service life1) W ═ Atα(0 < α < 1) in order toImproving the accuracy of the relation by time T0Changing the constants of the relation for the boundary, thereby using W as A1tα1(t≤T0) … … (formula 1) and W ═ A2tα2(T0< t) … … (formula 2). Preferably T0Time t is the boundary between the initial stage and the stable stage shown in FIG. 20(T0＝t0)。
Respectively at T ≤ T0And T0If the measured value of the wear amount for different times is 2 or more at < t, A can be calculated1、α1、A2And α2Therefore, formula 1 and formula 2 can be determined.
The elapsed time t is the time elapsed during which the machining is continued with the time point at which the new tool of the same specification is set to 0, and the machining is continued, and represents the same time for machining one workpiece 5 and the continuous machining is performed at the same speed, and the elapsed time t does not include the time required for replacing the tool, and therefore, the elapsed time t is proportional to the number of machining operations, that is, when the wear amount of the tool 2 from the time point at which the machining is started is W, the number of machining operations is x, and the constants are a ' and α ' (< 1), it is also possible to use W ═ a ' x ″α' means. As described above, if the workpiece and the machining conditions are the same, the wear amount of the tool depends on the elapsed time t, i.e., the machining amount.
< Structure of wear amount estimation System >
As shown in fig. 3, the control device of the machine tool 1 has a wear amount estimation system 10. The wear amount estimation system 10 is a system that estimates the wear amount of the tool 2 in the machine tool shown in fig. 1.
The wear amount estimation system 10 includes a storage unit 11, a measurement unit 12, a calculation unit 13, and an estimation unit 14. The storage unit 11 is implemented by a nonvolatile storage device such as a flash memory. The control unit including the calculation unit 13 and the estimation unit 14 is realized by an arithmetic Processing device such as a cpu (central Processing unit).
The storage unit 11 stores a linear transformation P representing an amount of wear of the tool 2 from a machining start time pointW, elapsed time t, and constant A1、A2、α1、α2A linear transformation from formula 1 to formula 2, wherein formula 1 is W ═ a1tα1(t≤T0) Wherein formula 2 is W ═ A2tα2(T0＜t)。
The linear transformation P stored in the storage unit 11 is determined from a plurality of measured values of the wear amount of the tool 2 of the same specification with respect to the elapsed time from the machining start time point. The same-specification tool 2 that determines the linear transformation P may be the same-specification tool of one specific machine tool, or may be the same-specification tool attached to another machine tool of the same specification. The "machine tools of the same specification" refer to machine tools that produce the same machined object by the same operation.
Here, the linear transformation P stored in the storage unit 11 will be described. The linear transformation P is determined, for example, as follows.
For a cutter, according to T being less than or equal to T0A of equation 1 is obtained by using a plurality of measured values of1And according to T0A plurality of measured values of < t and A of formula 22And α2. Specifically, equation 1 is based on the measurement versus time T0The wear amount of the previous time is calculated from a plurality of measured values. Equation 2 is based on the measurement with respect to the time of excess T0And calculating a plurality of measured values of the wear amount at the subsequent time. Preferably, formula 1 is a relational expression in an initial stage, and formula 2 is a relational expression in a stable stage. That is, T is preferable0Is the time t at the boundary between the initial stage and the stable stage shown in FIG. 20(T0＝t0). Also, the preferable formula 2 is based on t in FIG. 21The measured values thus far.
In addition, T0Can be set arbitrarily. Considering the accuracy of equation 1 and equation 2, T may be set according to the number of measurements0。
α1And α2Although not particularly limited, it is preferably less than 1, that is, α is stored in the storage unit 111 Formulas 1 and α less than 12A linear transformation P determined by equation 2 less than 1. The present inventors have conducted intensive studiesα found in the early stage and the steady stage1And α2Less than 1, the linear transformation P of the storage unit 11 is based on the removal α1And α2Since the noise is determined for the measurement value of 1 or more, the accuracy of the estimated wear amount of the tool can be further improved.
The storage unit 11 of the present embodiment stores information satisfying α1＞α2The present inventors found that the linear transformation P of the storage unit 11 is reduced by only satisfying α because the initial stage α is large and the transition from the initial stage to the stable stage is α small1＞α2And therefore the accuracy of the estimated wear amount of the tool can be further improved.
With respect to the data series i (i is 1, 2, … …, n) obtained in this way, a in formula 1 is expressed1 (i)And α1 (i)The following formula 3 is used as an initial wear model, and a of the formula 22 (i)And α2 (i)The following equation 4 is set as a stable wear model.
[ numerical formula 1]
[ numerical formula 2]
Next, the average value μ is calculated as shown in the following formulas 5 to 8, and the standard deviation σ is calculated as shown in the following formulas 9 to 12, with respect to the elements of each model.
[ numerical formula 3]
[ numerical formula 4]
[ numerical formula 5]
[ numerical formula 6]
[ number formula 7]
[ number formula 8]
[ numerical formula 9]
[ numerical formula 10]
Next, the vectors of the mean values are expressed by the following expressions 13 and 14, and the vectors of the standard deviations are expressed by the following expressions 15 and 16. In addition, the vector μ of the mean valuesx，μyVector of standard deviation σx，σyStored in the storage unit 11.
[ numerical formula 11]
[ numerical formula 12]
[ numerical formula 13]
[ numerical formula 14]
Next, each parameter is normalized. Specifically, for each data, the normalization parameter X is calculated as shown in the following equations 17 to 22(i)，Y(i)。
[ numerical formula 15]
[ number formula 16]
[ number formula 17]
[ numerical formula 18]
[ number formula 19]
[ number formula 20]
Next, the normalization parameter X of formula 19 and formula 22 is used(i)，Y(i)And is obtained from the following formula 23A linear transformation P is output. In addition, the linear transformation P is derived by the least square method.
[ numerical formula 21]
The storage unit 11 stores the linear transformation matrix as the linear transformation P obtained in this way for the tool 2 of the same specification.
The measurement unit 12 measures the amount of wear of the tool 2 during machining (operation) over an elapsed time from the machining start time point. The measuring unit 12 may measure the wear amount of the machining surface of the tool 2, or may determine the wear amount of the tool 2 by measuring the shape of the workpiece. The measurement unit 12 of the present embodiment measures a workpiece machined using the tool 2, for example, using an air micrometer, and obtains the wear amount of the tool 2.
The calculation unit 13 calculates expression 1 for the tool 2 in machining of the same specification. That is, the calculation unit 13 calculates the time T0Calculating W ═ A from the plurality of measurement values1tα1A of the relation shown1And α1. Thus, equation 1 representing the wear amount of the tool is determined.
The calculation unit 13 calculates A1And α1And equation 1 is determined using at least two or more measurements for a tool 2. The calculation unit 13 may use the time T from the machining start time0The measured value obtained by measuring all the processed objects up to this point may be used from the processing start time point to the time T0The measured value obtained by measuring a part of the processed object. Preferably, the calculation unit 13 calculates a using only the measurement value at the initial stage1And α1。
The estimation unit 14 reads out the linear transformation P from the storage unit 11, and estimates expression 2 after linear transformation of expression 1 calculated by the calculation unit 13 as expression 2 of the tool 2 being machined. When the calculation unit 13 calculates the expression 1 in the initial stage, the estimation unit 14 can acquire the expression 2 in the stable stage. By obtaining expression 2 by the estimating unit 14, it is possible to estimate the time T to exceed0Amount of wear with time。
Here, a method of estimating expression 2 by the estimating unit 14 will be described with reference to fig. 4.
Based on A calculated by the calculating part 131And α1Then, an initial wear model parameter x shown in the following equation 24 is obtained.
[ numerical formula 22]
Next, the average μ of equation 13 is read from storage unit 11xAnd standard deviation σ of equation 15xThen, a normalized initial wear model X is calculated according to the following equation 25.
[ numerical formula 23]
X1 and X2 in the above formula 25 are represented by the following formulae 26 and 27.
[ numerical formula 24]
[ number formula 25]
Next, the linear transformation P is read out from the storage unit 11, and a normalized steady wear model Y is calculated from the normalized initial wear model X.
Next, the average μ of equation 14 is read from storage unit 11yAnd the standard deviation σ of equation 16yThe stable wear model parameter y shown in equation 29 is obtained by inverse normalization of equations 28 to 30.
[ number formula 26]
y1＝σy1Y1+μy1… (type 28)
[ numerical formula 27]
y2＝σy2Y2+μy2… (formula 29)
[ number formula 28]
[ numerical formula 29]
A can be derived from the obtained stable wear model parameter of equation 292And α2. Thus, A of formula 2 is determined2And α2Therefore, equation 2 can be obtained.
In addition, the wear amount estimation system may further include: measuring the relative excess time T of a tool in machining0A wear amount measuring unit for measuring the wear amount of the workpiece; and a calculation unit for calculating expression 2 from the measurement value. In this case, the storage unit 11 may store the linear transformation P obtained from the expressions 1 and 2 acquired by the calculation unit.
< method for estimating amount of wear >
Next, a wear amount estimation method will be described with reference to fig. 5.
First, the storage unit 11 is prepared (step S1), and the storage unit 11 stores a linear transformation P in which the wear amount of the tool from the machining start time point is W, the elapsed time is t, and the constant is a1、A2、α1、α2A linear transformation from formula 1 to formula 2, wherein formula 1 is W ═ a1tα1(t≤T0) Wherein formula 2 is W ═ A2tα2(T0＜t)。
Next, the measuring unit 12 measures a plurality of wear amounts of the tool 2 during machining with respect to an elapsed time from the machining start time point (step S2). In this step S2, the time T is passed0Obtaining the time T by measuring the amount of wear0A plurality of measurements of.
Then, the calculation part 13 passesCalculating W-A from a plurality of measurements1tα1A of (A)1And α1(step S3). This makes it possible to obtain expression 1 for the tool 2 being machined with the same specification.
Next, linear transformation P is read from storage unit 11, and expression 2 obtained by linear transformation from calculated expression 1 is estimated as expression 2 of the tool being machined (step S4). This makes it possible to obtain equation 2 for the tool being machined.
By performing the above steps S1 to S4, expression 2, which is a relational expression indicating the wear amount with respect to the elapsed time from the machining start time point, can be specified for the tool 2 being machined. Therefore, the wear amount of the tool 2 during machining can be estimated with respect to the elapsed time from the machining start time point.
As described above, the wear amount estimation system and the wear amount estimation method according to the present embodiment read the linear transformation P from the storage unit 11, and estimate expression 2 obtained by linearly transforming expression 1 calculated by the calculation unit 13 as expression 2 of the tool 2 being machined.
As a result of intensive studies, the present inventors have found that the relationship between the elapsed time t from the machining start time and the wear amount W of the tool can be expressed by expressions 1 and 2. Further, the present inventors found that there is a linear transformation P from expression 1 to expression 2, and thus completed the present invention.
According to the present embodiment, equation 1 of the tool 2 being machined can be estimated by calculating and linearly transforming equation 1 based on the linear transformation P in the storage unit 11. Therefore, the accuracy of the estimated wear amount of the tool 2 can be improved.
In the present embodiment, the linear transformation P can be specified even when the amount of data relating to the tools 2 of the same specification is small. Therefore, the wear amount estimation system 10 can easily estimate the wear amount.
In the present embodiment, T is set to0The linear transformation P of the relational expression composed of the expressions 1 and 2 for one tool 2 is stored in the storage unit 11 as the vicinity of the boundary between the initial stage and the stable stage. Wear amount estimation system and wear of the present inventionThe quantity estimation method may include a storage unit 11 that stores linear transformation of a relational expression composed of three or more expressions, for example.
(correction system)
< Structure of correction System >
As shown in fig. 3, the control device of the machine tool 1 has a correction system 20. The correction system 20 is a system for correcting the position of the tool 2 in accordance with the wear amount of the tool 2 in order to machine the workpiece 5 into the same shape in the machine tool 1 shown in fig. 1.
The correction system 20 includes the wear amount estimation system 10 and the correction section 21 described above. The wear amount estimation system 10 estimates the wear amount of the tool 2 in operation with respect to the elapsed time from the machining start time point, based on expression 2 acquired by the estimation unit 14.
The correction unit 21 corrects the position of the tool 2 during operation based on the estimated wear amount. Specifically, the correction unit 21 calculates a correction amount of the position of the support unit 3 that supports the tool 2 in operation, based on the estimated wear amount, and transmits a correction command to the support unit 3. The correction unit 21 can employ a known technique.
< correction method >
As shown in fig. 6, the wear amount of the tool 2 in operation with respect to the elapsed time is estimated from the relational expression obtained by the wear amount estimation method described above (step S10).
Next, the correcting unit 21 calculates a correction amount of the position of the supporting portion 3 in accordance with the estimated wear amount (step S11). Next, a correction command is transmitted to the positioning means of the support 3 so that the position of the support 3 is changed in accordance with the correction amount. This enables the position of the support portion 3 to be corrected, and thus the position of the tool 2 during machining can be corrected in accordance with the amount of wear (step S12).
As described above, according to the correction system 20 and the correction method of the present embodiment, since the wear amount estimation system 10 described above is provided, the accuracy of the estimated wear amount can be improved. Therefore, in the machine tool 1 that performs machining using the same specification of the tool 2, the accuracy of correcting the position of the tool 2 can be improved.
Further, by specifying equations 1 and 2 in the wear amount estimation system, the wear amount can be estimated over the entire use period of the tool 2, and therefore measurement at regular intervals can be omitted. Therefore, the number of steps for performing the calibration can be reduced, and thus labor cost can be reduced.
(abnormality detection System)
< Structure of abnormality detection System >
As shown in fig. 3, the control device of the machine tool 1 has an abnormality detection system 30. The abnormality detection system 30 is a system for detecting an abnormality of the machine tool 1 in the machine tool 1 shown in fig. 1. The abnormality of the machine tool 1 includes an abnormality of the tool 2, a failure in supply of cooling water, and the like.
The abnormality detection system 30 includes the wear amount estimation system 10, the measurement unit, the abnormality determination unit 31, and the abnormality display unit 32. The wear amount estimation system 10 estimates the wear amount of the tool 2 during machining with respect to the elapsed time from the machining start time point, based on expression 2 acquired by the estimation unit 14.
After the wear amount is estimated, the measurement section measures the wear amount. Specifically, the measuring unit measures the shape of the machined workpiece after machining, and calculates the amount of wear of the tool 2 during operation. The measuring unit of the present embodiment is used in combination with the measuring unit 12 of the wear amount estimating system 10. The measurement unit of the abnormality detection system may be provided separately from the measurement unit 12 of the wear amount estimation system.
The abnormality determination unit 31 determines that an abnormality has occurred in the machine tool 1 when the difference between the wear amount estimated by the wear amount estimation system 10 and the wear amount measured for the tool 2 of the same specification exceeds a predetermined value. In the present embodiment, the abnormality determination unit 31 calculates a difference between the measured value and the estimated value, and transmits a command for displaying an abnormality to the abnormality display unit 32 when the difference exceeds a predetermined value.
The difference between the measured value and the estimated value may be a difference between the wear amount estimated from expression 2 acquired by the wear amount estimation system 10 and the measured wear amount, or may be a difference between expression 2 acquired by the wear amount estimation system 10 and expression 2 calculated by measurement.
As a specific example, fig. 7 shows a relational expression obtained by the wear amount estimation system and a measured value of the wear amount of the tool in operation. In fig. 7, the difference between the estimated wear amount and the measured value is large when the time 190 elapses. The abnormality determination unit 31 determines that the difference between the wear amount and the measurement value is larger than a predetermined value when the time 190 elapses.
Here, a predetermined value determined to be abnormal will be described. As shown in fig. 8, W(s) is a relational expression estimated by the wear amount estimation system 10 using the measurement values until the elapsed time snI t). If the time s is to be measurednIs set as E(s)n) For example, the expression is represented by the following three formulae 32 to 34. In equations 33 to 34, the measurement time at the ith measurement point is represented by siLet the wear loss be Wi。
[ number formula 30]
E1(sn)＝|W(sn|sn)-wn.
The above equation 32 is the time until the measurement snT is s in the above relationnError in time.
[ number formula 31]
The above equation 33 evaluates to the measurement time snRelation between time and measurement time sn-1The error between the relational expressions described above is a mean square error of each measurement point.
[ number formula 32]
The above equation 34 is a mean square error of the continuous palm grip 33.
Determining the previous measuring time sn-1Error index E(s) ofn-1) And calculating R(s) as its rate of changen)＝E(sn)/E(sn-1). At R(s)n) When the content is 0.5 or more and 1.5 or less, the steel is a gaugeWithin a constant value, in R(s)n) If the value is less than 0.5 or exceeds 1.5, the value exceeds a predetermined value.
Will be based on the error index E1(sn)～E3(sn) Calculated R(s)n) Shown in fig. 9 to 11. The measured values of the uppermost wear amounts in fig. 9 to 11 are the same as those in fig. 7. As shown in FIGS. 9 to 11, R(s) is detected when time 190 has elapsedn) Over 1.5.
The abnormality determination unit 31 determines that R(s) isn) When the time exceeds 1.5, it is determined that the machine tool 1 is abnormal. In addition, in the initial stage, R(s) may not be accurately determinedn) Therefore, the abnormality determination unit 31 may be set to R(s) in the steady staten) If the difference exceeds 1.5 and is less than 0.5, it is determined that the difference between the measured value and the estimated value exceeds a predetermined value.
The abnormality display unit 32 displays that an abnormality has occurred in order to notify the user of the abnormality in accordance with an instruction from the abnormality determination unit 31. The abnormality display unit 32 may be visually recognized or audibly recognized. The latter is, for example, a buzzer or the like that issues an alarm.
The control device for the machine tool 1 may further include a stopping unit that stops the operation of the machine tool 1 when the abnormality determination unit 31 determines that an abnormality has occurred in the machine tool 1. For example, if the difference between the measured value and the estimated value exceeds a predetermined value, the abnormality determination unit 31 sends a command to stop the operation of the machine tool 1 to the stop unit. The stop unit stops the operation of the machine tool 1 in response to a command from the abnormality determination unit 31.
The controller of the machine tool 1 may control the abnormality detection system to perform the on operation and the off operation. For example, the control device turns off the abnormality detection system in an initial stage, and turns on the abnormality detection system after entering a stable stage.
< method of detecting abnormality >
As shown in fig. 12, the wear amount of the tool 2 during operation with respect to the elapsed time is estimated by the wear amount estimation method described above based on expression 2 acquired by the estimation unit 14 (step S10). Next, the wear amount of the tool 2 in operation is measured (step S21).
Next, it is determined whether or not the difference between the wear amount estimated by the wear amount estimation system 10 and the wear amount measured with respect to the tool 2 being machined is within a predetermined value (step S22). If it is determined in step S22 that the value is within the predetermined value, the process proceeds to step S23. In step S23, since the machine tool 1 has no abnormality, the machining is continued by the same tool 2. On the other hand, if it is determined in step S21 that the value exceeds the predetermined value, the process proceeds to step S24. In step S24, it is determined that an abnormality has occurred in the machine tool 1.
As described above, according to the abnormality detection system 30 and the abnormality detection method of the present embodiment, since the wear amount estimation system 10 described above is provided, the accuracy of the estimated wear amount can be improved. Since an abnormality is determined by using the difference between the estimated wear amount and the measured wear amount, the accuracy of determining an abnormality in the machine tool 1 that performs machining using the same specification of the tool 2 can be improved. Further, since an abnormality occurring in the machine tool 1 can be detected at an early stage, defective products can be reduced.
(Life span detecting System)
< Structure of life detecting System >
As shown in fig. 3, the control device of the machine tool 1 has a life detection system 40. The life detection system 40 is a system for detecting the life of the tool 2 in the machine tool 1 shown in fig. 1. The life detection system 40 of the present embodiment early detects the change point from the stable stage to the final stage in fig. 2 as the life of the tool 2.
The life detection system 40 includes the wear amount estimation system 10, the measurement unit, the life determination unit 41, the life display unit 42, and the notification unit 43. The wear amount estimation system 10 determines equation 2 for the tool 2 in operation.
After determining equation 2, the measuring section measures the wear amount. Specifically, the measuring unit measures the shape of the machined workpiece after machining, and calculates the amount of wear of the tool 2 during operation. The measuring unit of the present embodiment is used in combination with the measuring unit 12 of the wear amount estimating system. The measuring unit may be provided separately from the measuring unit 12 of the wear amount estimating system.
If by measuring the tool 2 in processWhen the formula 2 calculated based on the wear amount changes from the formula 2 estimated by the wear amount estimation system 10, the life determination unit 41 determines that the life of the tool 2 is reached. The "change in expression 2" means that the shape of the graph shown in expression 2 changes, and does not include any change in the coefficient. Specifically, as shown in fig. 2, the relational expression At the final stage is such that W ═ At cannot be usedα(α < 1), and thus expression 2 changes.
In the present embodiment, the calculation unit 13 of the wear amount estimation system 10 calculates the expression 2 from the plurality of most recent measurement values of the tool 2 in operation, and the life determination unit 41 determines whether or not the shape of the expression 2 has changed. If it is determined that equation 2 has changed, the lifetime determination unit 41 sends a command for displaying the lifetime reached to the lifetime display unit 42.
The life determination unit 41 may determine that the tool 2 has a life when the difference between the wear amount estimated based on the expression 2 specified by the wear amount estimation system 10 and the wear amount measured with respect to the tool 2 in operation exceeds a predetermined value.
The present inventors have found that α in the initial stage and the steady stage shown in fig. 2 is less than 1, and α after reaching the lifetime exceeds 1, and therefore, the lifetime determination unit 41 of the present embodiment determines that the lifetime of the tool 2 has been reached when α exceeds 1.
The lifetime display unit 42 displays that the lifetime has been reached in response to a command from the lifetime determination unit 41. The life display unit 42 may be visually recognized or audibly recognized. The lifetime display unit 42 may be used as well as the abnormality display unit 32, or may be disposed separately.
The inventors have focused on the point that the life of the tool 2 is not easily predictable and is reached sharply. Therefore, the life detection system 40 includes a notification unit 43 that notifies the proximity life in advance. When the notification unit 43 notifies the approaching life, measures such as increasing the frequency of measurement can be taken, and therefore, the use of a tool whose life has exceeded can be suppressed. The notification unit of the present embodiment notifies the approaching lifetime from two viewpoints.
At W ═ AtαThe notification unit 43 from one viewpoint when α calculated from the measured value exceeds the maximum value less than 1 in the initial stageSpecifically, the calculation unit 13 calculates α from the most recent measurement values, and the notification unit 43 determines whether or not the calculated α exceeds the maximum value of less than 1 in the initial stage, and when α exceeds the maximum value of less than 1 in the initial stage, a command is sent to the display unit to give an alarm to notify that the tool 2 in operation is approaching the life.
The present inventors found that α in the initial stage is larger than α in the stable stage, as described above, the present inventors determined that α is noise in the initial stage, and found that the lifetime is approached when a maximum value of α which is smaller than 1 is measured in a state where no noise is present in the initial stage, and then a value exceeding the maximum value is measured.
The notifying unit from another viewpoint reads the life data from the storage unit 11 storing the life data of the tools of the same specification, and notifies the time of the life of the tools of the same specification. In the present embodiment, the storage unit 11 of the wear amount estimation system 10 also stores life data of a plurality of tools of the same specification. The notification unit 43 reads a plurality of lifetime data from the storage unit 11, selects the shortest lifetime, and notifies the proximity lifetime when the selected shortest time is reached. The notification unit performs control of the read storage unit 11, but the function of the notification unit can arbitrarily select the on operation and the off operation.
< method for detecting Life >
As shown in fig. 13, expression 2 is estimated for the tool 2 in operation by the wear amount estimation method described above (step S10). Next, a plurality of wear amounts of the tool 2 in operation are measured (step S21). Then, the calculation unit 13 calculates the machining time and the wear amount of the tool 2 in operation by equation 2 (step S31).
Next, it is determined whether or not expression 2 of the tool 2 in operation has changed from expression 2 determined by the wear amount estimation method (step S32). If it is determined in step S32 that no change has occurred, the process proceeds to step S33. In step S33, since the life of the tool 2 has not been reached, the machining is continued with the same tool 2. On the other hand, if it is determined in step S32 that a change has occurred, the process proceeds to step S34. In step S34, it is determined that the life of the tool 2 has been reached.
As described above, according to the life detection system 40 and the life detection method of the present embodiment, since the wear amount estimation system 10 described above is provided, the life can be determined by the change of equation 2. Therefore, in a machine tool that performs machining using tools 2 of the same specification, the accuracy of determining the life of the tool 2 can be improved. Further, since the life of the tool 2 can be detected at an early stage, defective products can be reduced by replacing the tool 2 having reached the life. Further, since the tool 2 can be used for a long life, it is advantageous in terms of cost.
Here, as shown in fig. 3, the machine tool 1 of the present embodiment includes a wear amount estimation system 10, a correction system 20, an abnormality detection system 30, and a life detection system 40. The machine tool of the present invention is not particularly limited as long as it has a wear amount estimation system, and may have any one or both of a correction system, an abnormality detection system, and a life detection system.
[ examples ] A method for producing a compound
(example 1)
In the present embodiment, a relational expression between the elapsed time t from the machining start time point of the tool and the wear amount W will be described.
First, in one machine tool 1, a metal workpiece 5 of the same specification is repeatedly machined under the same conditions using a tool 2, and the wear amount is measured. Fig. 14 shows data measured for 9 tools of the same specification. In fig. 14, an abnormality occurs in the cutter 4 in the region a. In the region B, the machine tool 1 is stopped.
Fig. 15 shows the measurement points where abnormality occurs as in the regions a and B, and the measurement values for normal operation extracted from fig. 14.
Next, fig. 15 shows the results of assuming that the time points at which the respective tools were replaced are machining start time points and are all 0, and inverting the vertical axis, as shown in fig. 16. The inventors stored the data shown in fig. 16As a result of intensive studies, it was found that W ═ At can be usedαThe relational expression (a and α (< 1) is a constant) shows the relationship between the elapsed time t from the machining start time point of the tool and the wear amount W, and the relational expression shown in fig. 16 is obtained by obtaining a geometric average of 9 relational expressions.
As described above, the present inventors have conducted extensive studies to determine a basic expression that is a relationship between elapsed time and wear amount, and as a result, have found that W ═ AtαThis relationship. The wear amount estimation system, the calibration system, the abnormality detection system, the life detection system, the machine tool, and the wear amount estimation method according to the present invention estimate the wear amount of the tool 2 using the found relational expression, and therefore can improve the accuracy of the estimated wear amount of the tool.
(example 2)
In the present embodiment, a is selected from the pair W ═ a1tα1(t≤T0) … … (formula 1) to W ═ A2tα2(T0< t) … … (equation 2).
The present inventors, after storing the data shown in fig. 16, found that by using T0Changing the constants of A and α for the boundary, and increasing W-AtαThe accuracy of the relation of (c). I.e., by making W ═ A1tα1(t≤T0) … … (formula 1) and W ═ A2tα2(T0< t) … … (expression 2) can further improve the accuracy of estimating the wear amount.
Will T0The time t is the boundary between the initial stage and the stable stage shown in FIG. 20(T0＝t0) In the same manner as in example 1, expressions 1 and 2 were obtained for 27 tools having the same specifications. Then, the inventors performed A on formula 11And α1And A of formula 22And α2As a result of intensive studies on the relationship between the two, it was found that there is a linear transformation P from expression 1 to expression 2 as shown in fig. 17 and 18.
Next, the accuracy of the wear amount estimation system having the storage unit 11 storing the linear transformation P was confirmed as follows.
Specifically, the storage unit 11 is prepared based on the measured values of 27 tools of the same specification shown in fig. 17 and 18, and stores the linear transformation P according to the embodiment (step S1). Next, the measuring unit 12 measures a plurality of wear amounts of the tool 2 of the same specification during machining with respect to the elapsed time from the machining start time point (step S2). Then, the calculation unit 13 calculates W ═ a from the plurality of measurement values1tα1A of (A)1And α1(step S3). Thereby, equation 1 for the tool 2 under machining is obtained.
Next, linear transformation P is read from storage unit 11, and expression 2 after linear transformation from calculated expression 1 is estimated as expression 2 of the tool being machined (step S4). Thus, equation 2 is obtained for the tool being machined. A according to formula 22Log obtained by10A2And α2Shown as an estimate in fig. 19.
And, after passing T0Thereafter, the measurement unit 12 also measures a plurality of wear amounts of the tool 2 during machining with respect to the elapsed time from the machining start time point. The results are shown as measured values in fig. 19.
As shown in fig. 19, it can be seen that the estimated value estimated by the wear amount estimation system of the present invention is approximate to the measured value. It was thus confirmed that the wear amount estimation system according to the present invention can improve the accuracy of the estimated wear amount of the tool.
It should be considered that the embodiments and examples disclosed herein are illustrative in all respects and not restrictive. The scope of the present invention is shown by the claims, and is intended to include not only the embodiments and examples described above but also all modifications equivalent in meaning and scope to the claims.
Claims (8)
1. A wear amount estimation system for estimating the wear amount of a tool in a machine tool that repeatedly machines a workpiece of the same specification under the same conditions using the tool,
the wear amount estimation system includes:
storage section, stationThe storage unit stores a linear transformation P in which a wear amount of the tool from a machining start time point is W, an elapsed time is t, and a constant is A1、A2、α1、α2A linear transformation from formula 1 to formula 2, wherein said formula 1 is W ═ a1tα1Wherein T is less than or equal to T0Wherein said formula 2 is W ═ A2tα2Wherein T is0＜t；
A calculation unit that calculates the formula 1 for the tools in machining of the same specification; and
and an estimating unit that reads out the linear transformation P from the storage unit, and estimates an expression 2 obtained by linearly transforming the expression 1 calculated by the calculating unit as the expression 2 of the tool being machined.
2. The wear amount estimation system according to claim 1, wherein,
the storage part stores the information according to α1Formulas 1 and α less than 12The linear transformation P determined by equation 2 less than 1.
3. The wear amount estimation system according to claim 2, wherein,
the storage section stores information based on satisfaction of α only1＞α2The linear transformation P determined by the above equations 1 and 2.
4. A correction system, comprising:
the wear amount estimation system according to any one of claims 1 to 3; and
a correction unit that corrects the position of the tool during machining based on the wear amount estimated by the wear amount estimation system.
5. An anomaly detection system, comprising:
the wear amount estimation system according to any one of claims 1 to 3; and
and a determination unit that determines that an abnormality has occurred in the machine tool when a difference between the wear amount estimated by the wear amount estimation system and the wear amount measured for the tool during machining exceeds a predetermined value.
6. A life detection system, comprising:
the wear amount estimation system according to any one of claims 1 to 3; and
and a determination unit that determines that the tool life has been reached when expression 2 calculated by measuring the wear amount of the tool during machining is changed from expression 2 estimated by the wear amount estimation system.
7. A machine tool, comprising:
the wear amount estimation system according to any one of claims 1 to 3;
the cutter is used for processing the processed object; and
a placement unit on which the workpiece is placed.
8. A wear amount estimation method for estimating a wear amount of a tool in a machine tool that repeatedly machines a workpiece of the same specification under the same conditions using the tool,
the wear amount estimation method includes:
a step of preparing a storage unit that stores a linear transformation P in which a wear amount of the tool from a machining start time point is W, an elapsed time is t, and a constant is a1、A2、α1、α2A linear transformation from formula 1 to formula 2, wherein said formula 1 is W ═ a1tα1Wherein T is less than or equal to T0Wherein said formula 2 is W ═ A2tα2Wherein T is0＜t；
Calculating the formula 1 for the cutting tools in the same specification; and
and a step of reading out the linear transformation P from the storage unit, and estimating expression 2 obtained by performing linear transformation from the calculated expression 1 as the expression 2 of the tool being machined.
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| JP2018166120A JP7196473B2 (en) | 2018-09-05 | 2018-09-05 | Amount of wear estimation system, correction system, anomaly detection system, life detection system, machine tool, and method of estimating amount of wear |
| JP2018-166120 | 2018-09-05 |
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| JP7196473B2 (en) | 2022-12-27 |
| CN110877233B (en) | 2021-12-07 |
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