JP2013248717A - Method for determining replacement timing of tap - Google Patents
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Abstract
Description
この発明は、タップの交換時期判定方法に関し、特に、主軸モータの電力値からタップの交換時期を判定する方法に関する。 The present invention relates to a tap replacement time determination method, and more particularly to a method of determining a tap replacement time from a power value of a spindle motor.
従来、タップの交換時期判定方法として、モータの駆動電流の変動を測定し、これを、標準負荷曲線、上限負荷曲線および下限負荷曲線などと比較して、モータの駆動電流の変動が所定の閾値以上となったときを交換時期とすることが知られている（特許文献１）。 Conventionally, as a method for determining the tap replacement time, the fluctuation of the driving current of the motor is measured and compared with a standard load curve, an upper limit load curve, a lower limit load curve, etc. It is known that the time when the above becomes the replacement time (Patent Document 1).
電流に代えて、主軸モータに取り付けられた電力計で得られる電力波形からタップの交換時期を判定することも行われている。 In place of the current, the tap replacement time is also determined from a power waveform obtained by a power meter attached to the spindle motor.
上記従来のタップの交換時期判定方法においては、電力波形のばらつきが大きいことから、交換時期の算出を精度よく行うことが困難であるという問題があった。そのため、安全を見越して早めにタップの交換を行う必要があり、タップ加工費用を低減することが困難であった。 In the conventional tap replacement time determination method, there is a problem that it is difficult to calculate the replacement time with high accuracy because the power waveform varies greatly. Therefore, it is necessary to replace the tap as soon as possible in anticipation of safety, and it has been difficult to reduce the cost of tapping.
この発明の目的は、上記の問題を解決し、タップの交換時期の算出を精度よく行うことを可能とし、これにより、タップ加工費用を低減することが可能なタップの交換時期判定方法を提供することにある。 An object of the present invention is to provide a tap replacement time determination method that solves the above-described problem and makes it possible to accurately calculate the tap replacement time, thereby reducing the tap processing cost. There is.
この発明によるタップの交換時期判定方法は、タップを使用してねじ孔の加工を行うに際し、主軸モータに電力計を取り付けて、得られた電力波形から前記タップの交換時期を判定する方法であって、前記タップによる加工状態を複数の区間に分け、所要の区間内における電力波形データを使用して前記タップの交換時期を判定することを特徴とするものである。 The tap replacement time determination method according to the present invention is a method of determining a tap replacement time from a power waveform obtained by attaching a power meter to a spindle motor when machining a screw hole using a tap. Then, the processing state by the tap is divided into a plurality of sections, and the replacement time of the tap is determined using power waveform data in a required section.
タップを使用してねじ孔の加工を行う場合、切込みが始まってから加工が完了するまでには、複数の加工状態がある。従来は、どのような加工状態にあるかを考慮せずに、電力波形に対して閾値が設定されて、タップの交換時期が判定されていた。この発明によるタップの交換時期判定方法においては、複数の加工状態のうちの例えば１つまたは２つの状態（例えば不完全ネジ部が下穴通過完了後など）の電力波形データを使用してタップの交換時期が判定される。これにより、電力波形のばらつきが小さくなり、タップの交換時期の算出を精度よく行うことができる。 When a screw hole is machined using a tap, there are a plurality of machining states from the start of cutting until the machining is completed. Conventionally, a threshold is set for the power waveform without considering what processing state it is in, and the tap replacement time is determined. In the tap replacement time determination method according to the present invention, the power waveform data of, for example, one or two of a plurality of machining states (for example, after the incomplete screw portion has completed passing through the pilot hole) is used. The replacement time is determined. Thereby, the dispersion | variation in an electric power waveform becomes small and the calculation of the replacement | exchange time of a tap can be performed accurately.
前記複数の区間は、不完全ネジ部の切込み中、前記不完全ネジ部全体が下穴通過中、前記不完全ネジ部が前記下穴通過完了後および前記タップを逆回転させてのタップ抜きを含んでおり、前記不完全ネジ部が前記下穴通過完了後の区間の平均電力値／前記不完全ネジ部が前記下穴通過中の区間の平均電力値が所定の閾値以上となったときをタップの交換時期とすることが好ましい。 In the plurality of sections, during incision of the incomplete screw portion, the entire incomplete screw portion is passing through the pilot hole, and after the completion of the incomplete screw portion passing through the pilot hole and by rotating the tap in reverse, tap removal is performed. And the average power value of the section after the incomplete screw portion has completed passing through the pilot hole / when the average power value of the section in which the incomplete screw portion passes through the pilot hole is equal to or greater than a predetermined threshold value. It is preferable to set the tap replacement time.
タップによる加工状態を複数の区間に分けると、不完全ネジ部が下穴通過中の区間においては、負荷電力がほぼ一定で推移し、加工数が所定数（交換時期に近い数）を超えても増加率がそれほど大きくならないのに対し、不完全ネジ部が下穴通過完了後においては、加工数が所定数を超えた時点で増加率が大きくなる。上記の不完全ネジ部が下穴通過完了後の区間（後述する区間Ｃ）の平均電力値／不完全ネジ部が下穴通過中の区間（後述する区間Ｂ）の平均電力値は、ワークのばらつきなどによって変動する絶対値ではなく比率とされていることで、ばらつきが抑えられ、しかも、加工数が所定数を超えた時点で増加率が大きくなる値になっている。したがって、この値に対して、閾値を設定することで、極めて精度よくタップの交換時期の算出を行うことができる。 If the machining state by tapping is divided into multiple sections, the load power will remain almost constant in the section where the incomplete thread is passing through the pilot hole, and the number of machining will exceed the predetermined number (close to the replacement time). However, the increase rate does not increase so much, but after the incomplete thread portion has passed through the pilot hole, the increase rate increases when the number of machining exceeds a predetermined number. The average power value of the section after the completion of passage of the incomplete screw portion (section C described later) / the average power value of the section of the incomplete screw section during passage of the pilot hole (section B described later) is Since the ratio is not an absolute value that fluctuates due to variations or the like, the variation is suppressed, and the increase rate becomes large when the number of processing exceeds a predetermined number. Therefore, by setting a threshold value for this value, the tap replacement time can be calculated with extremely high accuracy.
この発明のタップの交換時期判定方法によれば、上記のように、タップの交換時期の算出を精度よく行うことができる。これに伴い、１本のタップによる加工数を多くすることが可能となり、タップ加工費用を低減することができる。 According to the tap replacement time determination method of the present invention, the tap replacement time can be accurately calculated as described above. Along with this, it is possible to increase the number of processing by one tap, and it is possible to reduce the tap processing cost.
以下、図面を参照して、この発明の実施形態について説明する。 Embodiments of the present invention will be described below with reference to the drawings.
図１は、この発明のタップの交換時期判定方法が使用されるねじ孔加工装置の１例を示す概略構成図である。 FIG. 1 is a schematic configuration diagram showing an example of a screw hole machining apparatus in which the tap replacement time determination method of the present invention is used.
ねじ孔加工装置(1)は、タップ(3)を使用してワーク(W)にねじ孔(S)の加工を行うもので、タップ(3)を回転させる主軸モータ(2)と、主軸モータ(2)を制御するモータ制御装置(4)と、主軸モータ(2)の電力を計測する電力計(5)と、電力計(5)で計測された電力のデータ処理を行うパソコン(6)とを備えている。 The screw hole processing device (1) uses the tap (3) to process the screw hole (S) on the workpiece (W). The spindle motor (2) that rotates the tap (3) and the spindle motor Motor controller (4) that controls (2), wattmeter (5) that measures the power of the spindle motor (2), and personal computer (6) that processes the data of the power measured by the wattmeter (5) And.
主軸モータ(2)は、３相モータとされ、Ｕ相、Ｖ相、Ｗ相の３相への通電をインバータ制御して回転磁界を発生させ、モータ回転子を回転駆動するものとされている。 The main shaft motor (2) is a three-phase motor, and it is assumed that the energization of the three phases U phase, V phase and W phase is controlled by an inverter to generate a rotating magnetic field, and the motor rotor is driven to rotate. .
図２に示すように、タップ(3)は、一定の外径を有する完全ネジ部(3a)と、完全ネジ部(3a)に連なり徐々に外径が小さくなるテーパ状とされた不完全ネジ部(3b)とからなる。 As shown in FIG. 2, the tap (3) has a complete thread part (3a) having a constant outer diameter, and an incomplete thread which is tapered to the outer diameter gradually connecting to the complete thread part (3a). Part (3b).
ワーク(W)には、下穴(H)が設けられている。下穴(H)は、不完全ネジ部(3b)の先端径よりも大きい径に形成されている。下穴(H)内を不完全ネジ部(3b)が通過することで、下穴(H)が最終のねじ孔(S)に近い形状となり、これをさらに完全ネジ部(3a)が通過することで、ねじ孔(S)の加工が完了する。 The work (W) is provided with a pilot hole (H). The pilot hole (H) is formed to have a diameter larger than the tip diameter of the incomplete screw portion (3b). By passing the incomplete screw part (3b) through the pilot hole (H), the pilot hole (H) becomes a shape close to the final screw hole (S), and the complete screw part (3a) passes through this. This completes the processing of the screw hole (S).
パソコン(6)には、電力波形からタップ(3)の交換時期を判定する判定プログラムを含むタップ交換時期算出手段(7)が設けられている。 The personal computer (6) is provided with tap replacement time calculation means (7) including a determination program for determining the replacement time of the tap (3) from the power waveform.
タップ交換時期算出手段(7)では、タップ(3)による加工状態を複数の区間に分け、それぞれの区間内での変化や区間同士を比較することで、タップ(3)の摩耗状態や破損状態を判別して、タップ(3)の交換時期を算出している。 The tap replacement time calculation means (7) divides the machining state by the tap (3) into a plurality of sections, and compares the changes in each section and the sections, so that the wear state and breakage state of the tap (3) And the replacement time of the tap (3) is calculated.
複数の区間は、図２（ａ）に示す不完全ネジ部(3b)の切込み中（区間Ａ）、図２（ｂ）に示す不完全ネジ部(3b)の下穴(H)通過中（区間Ｂ）、図２（ｃ）に示す不完全ネジ部(3b)が下穴(H)通過完了（区間Ｃ）および図２（ｄ）に示すタップ抜き（区間Ｄ）の４つとされている。 A plurality of sections are in the process of cutting the incomplete screw part (3b) shown in FIG. 2 (a) (section A) and passing through the pilot hole (H) of the incomplete screw part (3b) shown in FIG. 2 (b) ( Section B) and incomplete screw part (3b) shown in FIG. 2 (c) are made into four parts, pilot hole (H) passing completion (section C) and tapping (section D) shown in FIG. 2 (d). .
図２（ａ）の不完全ネジ部(3b)の切込み中（区間Ａ）は、ワーク(W)の下穴(H)内に不完全ネジ部(3b)の一部または全部が入っている状態をいう。図２（ｂ）の不完全ネジ部(3b)の下穴(H)通過中（区間Ｂ）は、不完全ネジ部(3b)の先端部が下穴(H)から徐々に出て行っている状態をいう。図２（ｃ）の不完全ネジ部(3b)が下穴(H)通過完了（区間Ｃ）は、不完全ネジ部(3b)の全てが下穴(H)から出て、完全ネジ部(3a)によってねじ孔(S)が形成されていく状態をいう。図２（ｄ）のタップ抜き（区間Ｄ）は、タップ(3)を正回転させてのねじ孔(S)の加工が完了し、タップ(3)を逆回転させて加工前の位置に戻している状態をいう。 During incision (section A) of the incomplete screw part (3b) in FIG. 2 (a), a part or all of the incomplete screw part (3b) is in the prepared hole (H) of the workpiece (W). State. During the passage of the pilot hole (H) (section B) of the incomplete screw part (3b) in Fig. 2 (b), the tip of the incomplete screw part (3b) gradually goes out of the pilot hole (H). The state that is. When the incomplete screw part (3b) in FIG. 2 (c) is completely passed through the pilot hole (H) (section C), all of the incomplete screw part (3b) comes out of the pilot hole (H). A state in which the screw hole (S) is formed by 3a). Tap removal (section D) in Fig. 2 (d) completes the processing of the screw hole (S) by rotating the tap (3) forward, and reversely rotates the tap (3) to return to the position before processing. The state that is.
図２に示すように、タップ(3)を使用した１回のねじ孔(S)の加工において、区間Ａでは、電力が増加し、区間Ｂでは、電力がほぼ一定となり、区間Ｃでは、電力が減少し、区間Ｄでは、電力は小さい値でほぼ一定となる。 As shown in FIG. 2, in the processing of one screw hole (S) using the tap (3), the power increases in the section A, the power is almost constant in the section B, and the power in the section C. In section D, the electric power is small and almost constant.
図３には、加工数の増加に伴って、区間Ｂにおける平均電力値（区間内のデータ数の平均値）および区間Ｃにおける平均電力値（区間内のデータ数の平均値）がどのように変化するかを示している。同図において、区間Ｂおよび区間Ｃにおける平均電力値は、加工数の増加とともに、いずれもその値が少しずつ増加している。すなわち、区間Ｂおよび区間Ｃにおける平均電力値と加工数とは相関があるので、区間Ｂおよび区間Ｃにおける平均電力値を利用して、加工数の限界値（タップ交換時期）の判定が可能である。また、区間Ｂにおける平均電力値は、増加率がほぼ一定であるのに対し、区間Ｃにおける平均電力値は、区間Ｃ／区間Ｂ≧６０％と示している基準線を越えると、増加率が大きくなっている。このことから、区間Ｃの平均電力値／区間Ｂの平均電力値（＝不完全ネジ部が下穴通過完了後の区間の平均電力値／不完全ネジ部が下穴通過中の区間の平均電力値）を使用して、タップ交換時期の判定が可能である。 FIG. 3 shows how the average power value in the section B (average value of the number of data in the section) and the average power value in the section C (average value of the number of data in the section) are increased as the number of processes increases. Shows how it will change. In the figure, the average power values in the section B and the section C are increasing little by little as the number of processes increases. That is, since there is a correlation between the average power value in section B and section C and the number of processes, the limit value (tap replacement time) of the number of processes can be determined using the average power value in section B and section C. is there. The increase rate of the average power value in the section B is almost constant, whereas the increase ratio of the average power value in the section C exceeds the reference line indicating that the section C / section B ≧ 60%. It is getting bigger. From this, the average power value of the section C / the average power value of the section B (= the average power value of the section after the incomplete screw portion is completely passed through the pilot hole / the average power of the section where the incomplete screw portion is passing the pilot hole Value) can be used to determine the tap replacement time.
図４に、区間Ｃの平均電力値／区間Ｂの平均電力値を示す。同図において、（ａ）は、平均化処理を行わない場合を示し、（ｂ）は、（ａ）のデータを平均化処理した場合を示している。平均化処理は、平均化数ｎ＝５、すなわち、第Ｎ回目の加工を行った際に、第（Ｎ−４）回目の加工から第Ｎ回目の加工までの５回分の平均値を求めるようにした。図４から、平均化処理を行わない場合には、ばらつきが大きく、交換時期の算出精度に影響が出る可能性があるのに対し、平均化処理を行うことで、ばらつきが小さくなり、交換時期の算出精度が向上することが分かる。 FIG. 4 shows the average power value in section C / average power value in section B. In the figure, (a) shows the case where the averaging process is not performed, and (b) shows the case where the data of (a) is averaged. In the averaging process, the average number n = 5, that is, when the N-th machining is performed, an average value for five times from the (N-4) -th machining to the N-th machining is obtained. I made it. From FIG. 4, when the averaging process is not performed, the variation is large, which may affect the calculation accuracy of the replacement time. On the other hand, by performing the averaging process, the variation is reduced, and the replacement time It can be seen that the calculation accuracy of is improved.
図３および図４において、交換時期として、タップ(3)の有効径変化より算出した「有効径変化」が１つの基準になる。上記実施形態では、安全を見込んで、タップ交換の判定基準としては、例えば、区間Ｃの平均電力値／区間Ｂの平均電力値≧６０％が使用される。上記のように、算出精度が向上していることで、不必要な安全を見込む必要はなく、この判定基準に基づいて、無駄のないタップ(3)交換が可能となる。閾値６０％は、一例であり、判定基準を区間Ｃの平均電力値／区間Ｂの平均電力値≧７０％や区間Ｃの平均電力値／区間Ｂの平均電力値≧８０％とすることももちろん可能である。 In FIG. 3 and FIG. 4, the “effective diameter change” calculated from the effective diameter change of the tap (3) serves as one reference as the replacement time. In the above embodiment, for safety, for example, the average power value of section C / the average power value of section B ≧ 60% is used as the criterion for tap replacement. As described above, since the calculation accuracy is improved, it is not necessary to allow for unnecessary safety, and the tap (3) can be replaced without waste based on this determination criterion. The threshold value of 60% is an example, and it is of course possible to set the determination criterion to the average power value of section C / average power value of section B ≧ 70% or the average power value of section C / average power value of section B ≧ 80%. Is possible.
なお、図示省略するが、区間Ｄにおいても、区間Ｂや区間Ｃと同様に、加工数の増加に伴って、平均電力値が徐々に増加する。したがって、区間Ｄの平均電力値を使用しても、タップ交換時期の判定が可能である。すなわち、図２に示すように、複数の区間に分けるとともに、各区間ごとの平均電力値の変化を見ることにより、各区間の平均電力値の変化の特徴に基づいた精度のよいタップ交換時期の判定が可能となる。 In addition, although illustration is abbreviate | omitted, also in the area D, similarly to the area B and the area C, an average electric power value increases gradually with the increase in the number of processes. Therefore, even when the average power value of the section D is used, the tap replacement time can be determined. That is, as shown in FIG. 2, by dividing into a plurality of sections and observing the change in the average power value for each section, it is possible to determine the tap replacement timing with high accuracy based on the characteristics of the change in the average power value in each section. Judgment is possible.
上記のタップ交換時期の判定は、タップ(3)の摩耗による交換時期を算出するものであるので、加工中の突発的な異常（タップ(3)の折れや欠け）時には対応できない。この突発異常に対しては、図５に示すように、全ての区間について、現在加工波形と１個前加工の波形から計算した上限値および１個前加工の波形から計算した下限値とを比較することで対応できる。例えば、図５において、丸で囲んだような波形が出て、１個前加工波形の上限値を超えた場合、タップ(3)の突発異常との判定が可能であり、タップ(3)の交換時期の判定をさらに精度よく行うことができる。 Since the determination of the tap replacement time described above is to calculate the replacement time due to wear of the tap (3), it cannot be handled in the event of a sudden abnormality (tap (3) breakage or chipping) during processing. For this sudden abnormality, as shown in FIG. 5, the upper limit value calculated from the waveform of the previous machining and the lower limit value calculated from the waveform of the previous machining are compared for all sections. It can respond by doing. For example, in FIG. 5, when a circled waveform appears and the upper limit value of the previous processing waveform is exceeded, it can be determined that the tap (3) has a sudden abnormality, and the tap (3) The replacement time can be determined with higher accuracy.
(2)：主軸モータ、(3)：タップ、(3b)：不完全ネジ部、(5)：電力計 (2): Spindle motor, (3): Tap, (3b): Incomplete screw part, (5): Wattmeter
Claims (2)
前記タップによる加工状態を複数の区間に分け、所要の区間内における電力波形データを使用して前記タップの交換時期を判定することを特徴とするタップの交換時期判定方法。 When machining a screw hole using a tap, it is a method of attaching a power meter to a spindle motor and determining the replacement time of the tap from the obtained power waveform,
A tap replacement time determination method, wherein the processing state by the tap is divided into a plurality of sections, and the replacement time of the tap is determined using power waveform data in a required section.
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Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
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| CN105269085A (en) * | 2015-11-23 | 2016-01-27 | 哈尔滨电机厂有限责任公司 | Method for machining large-size internal threads through magnetic drill |
| JP2016163916A (en) * | 2015-03-06 | 2016-09-08 | 株式会社Ｉｈｉエスキューブ | Monitoring device |
| JP2018015493A (en) * | 2016-07-29 | 2018-02-01 | 京セラ株式会社 | Evaluation method and evaluation apparatus |
| DE112021002975T5 (en) | 2020-05-25 | 2023-03-16 | Fanuc Corporation | TOOL DIAGNOSTIC DEVICE |
Citations (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPS578053A (en) * | 1980-06-12 | 1982-01-16 | Toshiba Mach Co Ltd | Detecting method for tool breakage |
| JP2009226551A (en) * | 2008-03-24 | 2009-10-08 | Mitsubishi Electric Corp | Tool service life detecting method and tool service life detecting device |
-
2012
- 2012-06-04 JP JP2012126839A patent/JP5966633B2/en not_active Expired - Fee Related
Patent Citations (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPS578053A (en) * | 1980-06-12 | 1982-01-16 | Toshiba Mach Co Ltd | Detecting method for tool breakage |
| JP2009226551A (en) * | 2008-03-24 | 2009-10-08 | Mitsubishi Electric Corp | Tool service life detecting method and tool service life detecting device |
Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2016163916A (en) * | 2015-03-06 | 2016-09-08 | 株式会社Ｉｈｉエスキューブ | Monitoring device |
| CN105269085A (en) * | 2015-11-23 | 2016-01-27 | 哈尔滨电机厂有限责任公司 | Method for machining large-size internal threads through magnetic drill |
| JP2018015493A (en) * | 2016-07-29 | 2018-02-01 | 京セラ株式会社 | Evaluation method and evaluation apparatus |
| DE112021002975T5 (en) | 2020-05-25 | 2023-03-16 | Fanuc Corporation | TOOL DIAGNOSTIC DEVICE |
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| JP5966633B2 (en) | 2016-08-10 |
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