JP2003022108A - Abnormality management device of machine tool - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an abnormality management device of a machine tool capable of recording and reproducing operation video and operation data of the machine tool at a point of time when an abnormality is occurred by associating them with each other. SOLUTION: The abnormality managing device is constituted of one or more cameras 10 to define a processing area ARA or a machine movable part of the machine tool as an image pickup range, an image data generating part 12 to generate pieces of image data DT1 by every prescribed sampling time from an image picked up by the cameras, an operation data acquiring part 16 to acquire operating states of the machine tool by every prescribed sampling time as operation data from an NC device, an operation recording synthesizing means 16 to synthesize operation records PC at a certain point of time by synthesizing the image data with the operation data corresponding to the image data, an image file 15 to store the synthesized operation records and an image reproducing means 17 to reproduce the operation records in the image file. When the abnormality is occurred in the machine tool, cause analysis is promptly and exactly performed by reproducing the operation records.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an abnormality of a machine tool which can record and reproduce an image of the machine tool and an operating condition of the machine tool when the abnormality occurs. Regarding management device.

[0002]

2. Description of the Related Art In a conventional machine tool, when an abnormality occurs in the machine tool, after the machine tool is stopped by an alarm, the worker is in the machining area and is in the middle of machining, or the state of the tool. Furthermore, the operating state of the machine tool at the time when the abnormality occurs is checked to determine the cause.

[0003]

However, after the machine tool is stopped due to an alarm, the work state at the time of the abnormality and the actual operating state of the machine tool are lost, so the experience of the operator is limited. Judgment based on is an important factor. In this case, an inexperienced operator cannot properly investigate the cause, which makes it difficult to take appropriate measures after the alarm.

Therefore, it is conceivable to collect the image of the machine tool when an abnormality occurs and reproduce the image after an alarm occurs so that the cause can be easily investigated. , It takes a lot of time and effort to investigate the cause just by collecting and reproducing the image.

In view of the above circumstances, the present invention can record the operation image of the machine tool and the operation data of the machine tool at that time in association with each other when an abnormality occurs, and record them, and reproduce them as necessary. An object of the present invention is to provide a machine tool abnormality management device.

[0006]

The invention of claim 1 is NC
In a machine tool (1) driven and controlled by a device (22), at least one camera (10) having the processing area (ARA) of the machine tool or a movable part of the machine as an imaging range, the camera, and the camera. An image data generation unit (12) that generates image data (DT1) for each predetermined sampling time from the image captured by the operation data, and operation data that acquires the operation state of the machine tool for each predetermined sampling time from the NC device as operation data. Acquisition means (16), operation record synthesizing means (16) for synthesizing the image data generated by the image data generating section and operation data corresponding to the image data to synthesize an operation record (PC) at a certain time. ), An image file (15) for storing the operation record synthesized by the operation record synthesizing means, and an image replay for reproducing the operation record in the image file. Means (17), it consists of.

According to a second aspect of the invention, the image file is
It is configured such that the operation record (PC) for the latest predetermined time (for example, the latest 2-3 minutes) is always stored.

According to the invention of claim 3, the operation record (PC)
Has image data that captures the processing status of the workpiece (6) in the processing area, and the operation data corresponding to the image data is obtained by the machine tool processing the workpiece when the image data is acquired. Actual machining data (D1 to D10
Etc.).

According to a fourth aspect of the present invention, external input means (21) for receiving an image transmission request (C2) from the outside via the communication line (23) is provided, and when an image transmission request is made from the outside. Transmitting the operation record stored in the image file to the outside where the image transmission request is output,
The operation record transmission means (13, 17) is provided.

According to a fifth aspect of the invention, the operation record synthesizing means records the operation data as binary format data when synthesizing the operation records.

[0011]

According to the first aspect of the present invention, an operation record in which an image of a machining area or a movable part of a machine and operation data indicating an operation state of a machine tool at the time of sampling the image are generated and stored is generated and stored. Therefore, when an abnormality occurs in the machine tool, the cause can be quickly and accurately investigated by reproducing the operation record.

According to the second aspect of the present invention, when the abnormality occurs in the machine tool, the necessary information is the state of the machine tool in the vicinity of the time when the abnormality occurs. Will be possible.

According to the third aspect of the present invention, an abnormality relating to the machining of the workpiece, which frequently occurs, is accurately identified by the operation record in which the machining status of the workpiece and the actual machining data of the machining of the workpiece by the machine tool are combined. Can be judged.

According to the invention of claim 4, since the operation record of the machine tool can be acquired from the outside, it becomes easy to investigate the cause of the abnormality at a service center or the like which is away from the place where the machine tool is installed. It is possible to quickly respond to.

According to the fifth aspect of the invention, since the operation data is recorded as binary format data, it is possible to easily reproduce the abnormal state by a simulation or the like using the operational data, and the cause of the abnormality is generated. Can be quickly and accurately investigated.

The numbers in parentheses are for convenience of showing the corresponding elements in the drawings, and the present description is not limited to the description in the drawings.

[0017]

BEST MODE FOR CARRYING OUT THE INVENTION Embodiments of the present invention will be described below with reference to the drawings.

FIG. 1 is a block diagram showing an example of a machine tool abnormality management device to which the present invention is applied, and FIG. 2 is a diagram showing an example of operation records.

As shown in FIG. 1, the machine tool 1 has a frame 2 on which a main shaft 5 having a chuck 3 mounted thereon is rotatably driven about a Z axis. . A workpiece 6 to be machined is held on the chuck 3, and a tool rest 7 is movably driven on the frame 2 in the X-axis and Y-axis directions orthogonal to the Z-axis and centered on the Y-axis. And is rotationally driven and positioned in the direction of arrow B. A tool 9, such as a rotary tool or a turning tool, is detachably attached to the tool rest 7, and when the rotary tool is attached, the tool 9 is rotatably driven in the arrow A direction.

The frame 2 is provided with a CCD camera 10 so as to cover a space in which machining can be performed on a work by a machine tool, that is, a machining area ARA as an imaging range thereof. A plurality of CCD cameras are arranged in such a manner that an area in which a machine moving part such as a tool changing device or a tool storing device frequently causes an abnormality is an imaging range.

An image recording control unit 12 constituting an abnormality management device 11 is connected to the CCD cameras 10,
The abnormality management device 11 includes an image file 15, an image editing unit 16, an alarm image reproducing unit 1 in addition to the above-described image recording control unit 12 connected to the main control unit 13 via a bus line 14.
7, an alarm detection unit 19, a display 20, a communication control unit 21, and the like are connected.

An NC device 22 for driving and controlling each control axis of the machine tool 1 and an auxiliary machine is connected to the image editing section 16, and the NC device 22 and the abnormality management device 11 are connected to the frame 2.
It is installed in a form that is integrated into the exterior. It should be noted that the NC device 22 and the abnormality management device 11 do not necessarily have to be integrated and arranged in a form that they seem to be integrated with each other, and may be separately arranged.

A service center 25 operated by a machine tool maker or the like is connected to the communication control unit 21 via a communication line 23 such as a wired / wireless public communication line.

Since the machine tool 1 and the like have the above-described structure, the machining with the machine tool 1 is performed with the workpiece 6 to be machined held on the chuck 3 as shown in FIG.
The C device 22 appropriately drives the spindle 5 and the tool rest 7 in accordance with a machining program stored in a memory (not shown) to perform predetermined machining by the tool 9 mounted on the tool rest 7.

When the machining of the work 6 by the NC device 22 is started, the machining start signal S1 is sent to the abnormality management device 1
1 is output to the main control unit 13 via the image editing unit 16, and the main control unit 13 receives this and receives the image recording control unit 12
In response, the CCD camera 10 is instructed to capture an image of the operating state of the machine tool, in particular, the processing state of the workpiece in the processing area ARA.

The image recording controller 12 drives a plurality of CCD cameras 10 to capture the operating conditions of a tool changing device and a tool storage device (not shown) as an image such as a still image or a moving image, and at the same time, in the processing area ARA. Similarly, the processing status of the work 6 is captured as an image. The image thus captured is sampled by the image recording control unit 12 at predetermined time intervals and output to the image editing unit 16 as image data DT1.

In the image editing unit 16, the image recording control unit 12
In synchronism with the sampling time of the image data DT1 at, the operating conditions of the machine tool at that time, that is, the rotational speed of the spindle, the feed rate, the coordinate position of the tool edge,
The C-axis positioning angle of the spindle, the load ratio of each axis at that time, and other important data for the operation of the machine tool and the machining of the work are acquired as the operation data DT2.

The image editing section 16 synthesizes the image data DT1 sent from the image recording control section 12 and the operation data DT2 acquired from the NC unit 22 at that time, and records them in the image file 15 as an operation record PC. To do.

As shown in FIG. 2, the operation record PC is a frame FM in which image data DT1 at the same sampling point and operation data DT2 of the corresponding machine tool corresponding to the image are combined. The operation record PC shown in FIG. 2 has image data DT1
The operation data DT2 is an image that captures the machining status of the workpiece 6 in the machining area ARA, and the operation data DT2 indicates that the tool spindle rotation speed at that time (the machining indicated by the captured image data DT1 is machining with a rotary tool, The rotation speed of the mounted rotary tool is recorded) D1, feed speed D2, X
Axis coordinate position D3, Y axis coordinate position D4, Z axis coordinate position D
5, C axis positioning angle D6, tool spindle load ratio D7, X
Actual machining data such as the feed axis load ratio D8, the Y feed axis load ratio D9, and the Z feed axis load ratio D10 that the machine tool is machining the workpiece 6 at the time of the sampling (in the value specified on the machining program, Image data DT1 and driving data DT2 are the same frame F.
It is stored and recorded in M.

The operation data DT2 is recorded in the frame FM in binary format, but it may be stored in the frame FM in the form of image information. It should be noted that the operation data DT2 is stored in a binary format, which is convenient because the operation data DT2 can be used as it is for a simulation or the like when investigating the cause of an abnormality later.

Therefore, by referring to the frame FM, the machining state of the workpiece 6 and the operating state of the machine tool at a certain point can be immediately known. The operation record PC is the processing area AR
Not only the image data DT1 captured by the CCD camera provided for capturing A, but also the CC provided at another position
The image data DT1 captured by the D camera is also generated. In that case, the driving data DT2 combined with the same frame FM is combined with the driving data DT2 relating to the image recorded by the image data DT1. For example, when the image data DT1 is related to the tool changer, the operation data DT2 is also combined with various kinds of operation / control data for the tool changer.

In this way, the image sent from each CCD camera is converted into image data D at a predetermined sampling time.
The image editing unit 16 combines the operation data DT2 corresponding to T1 as an operation record PC, and the image file 1
Sequentially stored in 5. The driving record PC stored in the image file 15 is sequentially stored in the image editing unit 16 at each sampling time, but in the image file 15, the driving record PC is output from the image editing unit 16. The operation record PC is stored for the latest 2-3 minutes, and the old operation record PC before that is discarded every time a new operation record PC is input. Therefore, the image file 15 always contains the latest operation record PC.
Will be stored for a predetermined time.

Thus, the machining of the work 6 of the machine tool 1 is executed, but for some reason, the machine tool 1
If an abnormality occurs in the operation of the NC device 2
2 detects the abnormality and immediately stops the operation of the machine tool, and outputs an abnormality detection signal S2 to the main controller 12 via the alarm detector 19. When the abnormality detection signal S2 from the NC device 22 is input, the main controller 12 receives the image recording controller 1
2 and the image editing unit 16 to stop the image capturing operation and the operation recording PC generating operation after a predetermined time,
The abnormality detection signal S2 is analyzed to determine in which part of the machine tool 1 the abnormality has occurred. Since the abnormality detection signal S2 includes information indicating the portion where the abnormality has occurred, it is possible to easily determine in which part of the machine tool 1 the abnormality has occurred.

Next, the main control section 12 causes the alarm image reproduction section 17 to record the operation record P for the portion in which the abnormality of the machine tool occurs up to the time when the abnormality detection signal S2 is input.
Command the storage of C. In response to this, the alarm image reproducing unit 17 records the image of the corresponding portion in the driving record PC.
To a separate file.

The operator can use an appropriate input means such as a keyboard to determine the cause of the abnormality by issuing an image reproduction command C.
1 is input to the alarm image reproduction unit 17 via the main control unit 12, and in response to this, the alarm image reproduction unit 17 stores the operation record PC, which is stored in another file, regarding the portion where the abnormality of the machine tool has occurred. Play on the display 20. As described above, the driving record PC shows the image data DT1 for a predetermined time immediately before the abnormality occurs, that is, for a straight line of 2 to 3 minutes.
Since the operation data DT2 such as the current position and the load of the machine tool portion corresponding to the image data and the image data are combined and continuously recorded at every predetermined sampling time (for example, every one second), By reproducing them on the display 20, the behavior of the machine tool in the vicinity of the time when the abnormality occurs is accurately grasped, and the operation data DT2 stored in the binary format is analyzed to analyze the abnormal state,
It becomes easy to deal with it.

The operation record PC can also be transmitted from the outside to the outside via the communication line 23. That is,
When an image transmission request C2 is input to the communication control unit 21 from the external service center 25 or the like via the communication line 23, the main control unit 12 causes the alarm image reproduction unit 17 to notify the corresponding operation record PC that an abnormality has occurred. Command the transmission of. In response to this, the alarm image reproducing unit 17 immediately outputs the corresponding operation recording PC to the service center 25 via the communication control unit 21 and the communication line 23, and the service center 25 reproduces the operation recording PC. , Verify the behavior of the machine tool near the time when the abnormality occurred, and use it to investigate the cause.

The machine tool on which the abnormality management device 11 is mounted is not limited to the lathe shown in FIG. 1, but may be any machine tool such as a machining center or a milling machine.

[Brief description of drawings]

FIG. 1 is a block diagram showing an example of an abnormality management device for a machine tool to which the present invention is applied.

FIG. 2 is a diagram showing an example of an operation record.

[Explanation of symbols]

1 ... Machine tool 6 ... Work 10 ... Camera 12 ... Image data generation unit (image recording control unit) 13 ... Image transmission means (main control unit) 15 ... Image file 16 ... Operation data generation unit ( Image editing unit 17 ... Image reproducing unit, image transmitting unit (alarm image reproducing unit) 21 ... External input unit (communication control unit) 22 ... NC device 23 ... Communication line C2 ... Image transmission requesting PC ... Operation records D1 to D10 ... Processing data

   ─────────────────────────────────────────────────── ─── Continued front page    (72) Inventor Masayoshi Mizumon             Aichi Prefecture Oguchi-machi Oguchi-machi Large-scale small-scale character boarding number 1               Yamazaki Mazak Co., Ltd. Head Office Factory (72) Inventor Hajime Ohashi             Aichi Prefecture Oguchi-machi Oguchi-machi Large-scale small-scale character boarding number 1               Yamazaki Mazak Co., Ltd. Head Office Factory (72) Inventor Isamu Isamu             Aichi Prefecture Oguchi-machi Oguchi-machi Large-scale small-scale character boarding number 1               Yamazaki Mazak Co., Ltd. Head Office Factory F term (reference) 5H223 AA06 BB04 CC06 DD03 DD07                       EE30 FF03 FF05 FF08                 5H269 AB01 BB11 KK03 NN18

Claims (5)

[Claims] 1. A machine tool driven and controlled by an NC device, wherein at least one camera having a machining area or a machine movable portion of the machine tool as an image capturing range, the camera is provided with a predetermined image from an image captured by the camera. An image data generation unit that generates image data for each sampling time, an operation data acquisition unit that acquires the operation state of the machine tool at each predetermined sampling time as operation data from the NC device, and an operation data acquisition unit that is generated by the image data generation unit. Image data,
An operation file combining means for combining operation data corresponding to the image data to combine an operation record at a certain time, an image file for storing the operation record combined by the operation record combining means, An abnormality management device for a machine tool, comprising an image reproducing means for reproducing an operation record. 2. The machine tool abnormality management apparatus according to claim 1, wherein the image file always stores the operation record for the latest predetermined time. 3. The operation record has image data that captures the processing status of the work in the processing area, and the operation data corresponding to the image data is obtained by the machine tool when the image data is acquired. The machine tool abnormality management device according to claim 1, which is actual machining data for machining a machine. 4. An external input means for externally inputting an image transmission request via a communication line is provided, and when the external image transmission request is made, the operation record stored in the image file is displayed. 2. The machine tool abnormality management apparatus according to claim 1, further comprising operation record transmission means for transmitting the transmission request to the outside. 5. The machine tool abnormality management device according to claim 1, wherein the operation record synthesizing unit records the operation data as binary format data when synthesizing the operation records.