JP2702055B2 - Automatic processing equipment - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an FMS (flexible production system) for automatically controlling a plurality of processing units including automatic machine tools such as a machining center together with ancillary equipment and automatically performing machining.

[0002]

2. Description of the Related Art FIG. 15 shows a conventional example of the FMS. This FMS has a plurality of machining centers MC
1 to MCn and a storage section (not shown) for each of the workpieces before and after processing are connected by a carrier 4 moving along the workpiece transport path 2. Each of the machining centers MC1 to MCn attaches a tool selected from the tool magazine 6 to the spindle 8 according to a predetermined program, and performs predetermined processing on a work on the table 10.

The tool magazines 6 of the machining centers MC1 to MCn each have a frequently used general-purpose tool (hereinafter referred to as a permanent tool) used for general machining.
Is stored over a plurality of types. The tool magazine 6 is provided with a tool carrier 14 moving on a tool transport path 12.
The tool is connected to the tool stocker 16 via the. And is supplied with a tool from the tool stocker 16 as necessary, or returns the tool to the tool stocker 16.

[0004] The tool stocker 16 stores spare tools for permanent tools stored in each tool magazine 6 or special tools used only for specific machining. The tool stocker 16 supplies a tool via the tool carrier 14 when a tool used in a machining center is damaged or worn out, or when machining using a special tool is required in any one of the machining centers. Thereby, the function of increasing the possibility of the type of machining in each machining center or reducing downtime due to tool loss is achieved.

Accordingly, the tool stocker 16 stores all kinds and numbers of tools required in each machining center during a predetermined continuous automatic operation (for example, at night) without excess or shortage. is necessary.

[0006]

By the way, during the automatic operation period, machining using the same special tool may be performed simultaneously in a plurality of machining centers. 16,
It is necessary to store the same tools in a number corresponding to the number of machining centers, which causes a problem that various restrictions are imposed on the automatic operation.

That is, since the number of tools that can be stored in the tool stocker 16 is limited to a certain value, if a plurality of special tools are to be stored in an overlapping manner, the types of tools stored in the entire tool stocker 16 are changed. Less and therefore
During the automatic operation period on the assumption that no external tools are replenished, the machining center and the tool stocker 16
Therefore, machining can be performed only within the range of tools stored in the automatic operation, and the types of machining that can be performed during automatic operation are limited.

It is conceivable to increase the capacities of the tool magazine 6 and the tool stocker 16 in order to solve the above-mentioned limitation. However, if these capacities are excessive, the cost increases and the selection range becomes wide. There is a problem that it takes a long time to perform a process of selecting one necessary tool, and thus the work efficiency is reduced.

The present invention has been made in view of the above circumstances, and by appropriately controlling the order of machining in the FMS, the tool stock section can store more types of tools, and the efficiency of the FMS can be improved. The purpose is to realize a continuous operation.

[0010]

In order to achieve the above object, according to the first aspect of the present invention, a tool is exchanged in accordance with an order set in a tool schedule table in a time series manner. A plurality of processing units each including an automatic machine tool that performs a machining process, a stock unit that stores tools used in these processing units, a work transfer unit that loads or unloads a work to or from the plurality of processing units, a tool-carrying unit for carrying the tool between the stock unit and the processing unit, these machining unit, the stock unit, workpiece transfer unit, and the automatic processing system and a control unit for controlling the tool-carrying portion, wherein A machining level table that stores the tools to be set in the tool schedule table and their machining times, and a machining order table that stores the machining order of each machining unit
And used for pre-machining that is performed as needed for each tool
A pre-machining tool table that stores pre-machining tools, and each tool
This tool completion table stores whether or not the specified machining has been performed.
And a schedule setting unit that compares setting contents for each tool of each processing unit set in the tool schedule table, displays a comparison result, and changes setting contents as necessary , and the control unit. Is the pre-machining tool
Refer to the table and this tool completion table
Machining on condition that machining with a tool has been completed
Execute the tool schedule if not completed.
Is configured to execute processing with the next tool on the
It is characterized by having been done . According to a second aspect of the present invention, in the automatic machining apparatus according to the first aspect, the machining level table stores a plurality of tools classified and stored, and the schedule setting unit sets the machining order table for each of the classified tools. It is characterized by comparing the contents and changing the settings. According to a third aspect of the present invention, in the automatic machining apparatus according to the second aspect, the machining level table classifies tools according to a machining priority order for a workpiece. According to a fourth aspect of the present invention, in the automatic machining apparatus according to any one of the first to third aspects, the control unit determines whether or not there is an unusable tool set in the machining order table. When there is an impossible tool, the processing unit is controlled to omit the processing by the tool in the tool schedule table.

[0011]

According to the above arrangement, by referring to the tool schedule table for each tool, the schedule setting section determines whether or not the tools are used repeatedly during the same time. By changing the order in which the tools are used, it is possible to establish a schedule that does not use the tools repeatedly.

Further, a pre-processing tool table and a main processing
Complete the machining of the tool corresponding to the pre-machining in the completion table
By referring to the completion of
It is determined whether machining is possible or not.
Automatically performs post-processes that become impossible due to tool loss
Can be omitted.

[0013] The schedule is compared for each tool classification.
By doing, for example, for a certain tool,
After the completion of machining, perform machining with the tool.
Can be.

Based on the presence or absence of unusable tools,
To determine whether or not each process in the ingredient schedule can be executed
Therefore, if some tools are lost during automatic operation,
To process other parts by omitting the processing by the tool
Can be.

[0015]

DESCRIPTION OF THE PREFERRED EMBODIMENTS Referring to FIG. 1, the configuration of the entire system of the present invention will be described. Reference numeral 20 denotes a schedule setting unit constituted by, for example, a personal computer or the like. The schedule setting unit 20 is supplied with data on the main machining program from a storage unit 22 that records the contents of a series of machining to be performed on each work in the system. The schedule setting unit 20 is connected to an FMS controller 24 that controls the entire processing system, and is connected to storage units 26 , 27 , 28 , 30, and 32 that store tables of various data necessary for processing schedule adjustment. Have been.

The storage unit 26 stores a processing level table. The processing level table 26 defines the processing order for each work based on the main processing program. The storage unit 27 stores a processing order table indicating a processing order for each of the machining centers MC1 to MC3 for each tool. The storage unit 28 stores the tool use order stored in the machining order table and the tool use schedule in consideration of the respective machining time and tool change time in a time-series manner. The storage unit 30 stores a tool completion table. This tool completion table stores the fact that a series of machining (machining of one block) to be performed by one tool has been completed in each machining. The preprocessing table 32 is stored in the storage unit 32. The pre-machining table 32 stores, for the main tool used in the main machining, tools necessary for the pre-machining, and also stores whether or not the pre-machining by the tool is completed. Further, the storage unit 32 stores a processing time table. The machining time table 32 extracts a tool used for each machining from the main machining program and stores the machining time.

An input unit 34 such as a keyboard is connected to the schedule setting unit 20 so that an input such as data rewriting can be made. In the embodiment, three machining centers MC1 to MC
3 (n = 3) constitutes the FMS.

Next, a description will be given of an example of a case where predetermined processing is performed on a machine component as shown in FIG.

The work W shown in FIG. 2 has a rectangular parallelepiped shape with a part cut away, and is formed by the following machining. a. Milling of each surface of I, II, III, IV, V, VI1, VI2. That is, the machining center MC of the embodiment
Assuming that i is a horizontal milling machine, a work W whose upper and lower surfaces (I and II) have been previously milled is placed on a table, and III, IV, V, VI1 and V
The four surfaces of I2 (the two surfaces are formed at the same indexing angle) are sequentially processed by a tool T1 (specifically, a milling cutter) to be processed into a predetermined shape. b. Boring using a boring bar for the large diameter hole 36. Specifically, a hole 36 having a predetermined inner diameter is formed by inner peripheral cutting using the inner peripheral rough machining tool T2 and the finishing machining tool T3. c. Processing of the holes 38, 40, 42, 44 on the respective surfaces by drills T4, T5, T6. d. Processing of some holes 40 and 42 by taps T7 and T8.

Taking the case of plane III as an example,
The processing of -d is performed in the following order. Surfaces III, IV, V, VI1, V using T1 milling cutter
Processing for I2. Drilling of four holes 38 on the surface III with the drill T4. Prepared hole processing by drill T6 for four holes 42 on surface III Screw processing by tap T8 on the prepared hole. Boring bar T2 for the inner circumference of hole 36 in plane III
Roughing by T3 and finishing by T3.

The main processing program 22 stores the contents of the processing performed in each of the machining centers MC1 to MC3, and data on the loading and unloading of the work to and from these devices. The schedule setting unit 20
On the basis of the supplied main machining program, the contents of machining performed in the machining center are analyzed for each tool, and a machining level table as shown in FIG.
To memorize.

In the machining level table, a series of machining performed by the same tool is regarded as one block, and the used tool, machining time, and machining level are stored for each block. For example, the processing of four holes 42 by T6 is block 5, and the processing of these holes by T8 is block 6. Here, the machining level 1 refers to the machining to be performed prior to all the machining, the machining level 2 refers to the machining in which the completion of the machining level 1 is inevitable in order to execute the machining, and the machining level 3 refers to the same. Processing in which the completion of processing level 2 is inevitable.

Specifically, in the work shown in FIG. 2, milling of each surface corresponds to level 1, preparation or roughing of each hole corresponds to level 2, and finishing or tapping of holes. This corresponds to level 3. The time required for tool change (time between Ti and Ti + 1) is one minute.

T1 to T4 to T2 to T6 to T6 shown in FIG.
The processing of T6 to T5 to T3 to T8 to T7 is set in the processing order table 27. From the set machining order table 27 and the use time and exchange time of each tool, level 1
(Processing in the tool T1) is set in the tool schedule table 28 of each machining center. Level 1
Is only processing by T1, there is no room for changing the order of use of the tools. Therefore, as shown in FIG. 4, the processing by MC1 in T1 is completed and the predetermined exchange time elapses in MC2. Waiting time INT1
(= 21 minutes), and a waiting time INT2 (= 42 minutes) until the processing in the MC2 is completed and a predetermined replacement time elapses is set in the MC3.

The contents of the tool schedule table 28 in which the waiting time is set as described above, or the fact that the use of the tool T1 is duplicated are indicated on the display of the schedule setting unit 20 or the input unit 34 such as a personal computer. Displayed and recognized by the operator. The operator determines, based on such a display, whether or not to proceed to the next level of processing while the waiting time remains.

Normally, in order to avoid such a waiting time, the number of tools T1 is prepared in the tool stocker 16 corresponding to the number of machining centers (= 3), or the tools T1 are provided to each machining center as permanent tools. The process of adopting each is taken by the operator. And T1
Are input from the input unit 34 at the same time, the tool schedules of MC2 and MC3 are processed such that the processing of T1 is performed in each machining center without generating INT1 and INT2. Table 28 is set.

The tools T2, T4, T5 and T6 corresponding to level 2 are extracted from the machining level table, and the machining by these is set in the machining order table 27 for MC1. Based on this setting, the tool schedule table 28 of MC1 is set as shown in FIG.

The processing order for MC2 is set in the processing order table 27, and duplication is checked. For level 2, if the same processing order as MC1 of T4 to T2 to T6 to T6 to T5 is set according to the processing level table 26, naturally, MC1
Is determined to overlap. Furthermore, the first tool T
It is determined whether there is a spare tool (or a permanent tool) for No. 4 and if there is no spare tool, the machining order set in the machining order table 27 is shifted to T2 to T6 to T6. A processing order of T5 to T4 is set.

A tool schedule table 28 is set as shown in FIG. 6 according to the shifted machining order, and it is determined whether the same tool is used on the same time axis. According to the tool schedules of FIGS. 5 and 6, since the use of the tool T6 is duplicated,
The processing sequence set in the processing sequence table 27 is shifted, and the same determination is repeated.

By setting the processing order of T2 to T6 to T5 to T4 to T6, a tool schedule table 28 as shown in FIG. 7 is obtained. Comparing the tool schedule table of FIG. 7 with the tool schedule table of FIG. 5, there is no simultaneous use of the same tool in both, and therefore, the tool schedule table of FIG.

Further, the same processing is performed for MC3. In the case of the embodiment, the tool T6 is used for a total of six processes twice in three machining centers despite the fact that the number of processes included in level 2 is five,
No matter how the machining order table 27 of the MC 3 is shifted, the duplication is not eliminated. Therefore, it is displayed on a display or the like that T6 overlaps and that it is impossible to avoid the overlap. The operator, according to the display, a. The tool T6 is adopted as a permanent tool in each machining center. b. The tool T6 is added to the tool stocker 16 to enable the simultaneous use of the tool T6. c. The main processing program 22 is modified so that another work is processed in the MC3. d. Processing by T6 in MC3 is stopped. e. As shown in FIG. 8, a schedule is set so that processing is performed after a predetermined waiting time INT3 for the tool T6 in which overlap has occurred. And set a condition corresponding to this.

Further, when the same processing is performed for level 3, the tool schedule table 28 for each machining center is completed.

The above processing performed by the schedule setting section 20 is shown in the flowchart of FIG. 9 and FIG. That is, in the processing for level 1, a tool schedule is set for each machining center (SP1), and the presence / absence of duplication of tools in the set schedule and the waiting time are displayed (SP1).
2) The operator determines whether or not to approve the schedule (SP3). If approved, terminates the process. If not approved, changes in conditions for measures such as adding a spare tool are input. After that (SP4), the processing of SP1 and below is repeated again.

In the processing for level 2, M
Set a schedule for C1 and MC2 (SP
10, 11), and it is determined whether or not there is duplication of tools (SP1).
2) If they overlap, the processing order in MC2 is shifted (SP14), and the process returns to SP11. If they do not overlap, the schedule is set for MC3 (SP15). Further, it is determined whether or not the tool is repeatedly used in the MC3 (SP16). If the tool is not overlapped, the process is terminated. If the tool is overlapped, the processing order is shifted (SP16).
18) Return to SP15 and repeat the setting. Further, when it is determined that there is a bob, it is determined whether or not shifting has been performed for all combinations (SP13, SP1).
7) If there is no room for further shifting, a message indicating that there is a slap and a tool in which the slap has occurred are displayed and the operator's judgment is asked (SP19). In addition, when the condition is changed by the operator's judgment, for example, when a tool is added,
The above processing is repeated based on the condition.

The automatic operation of the automatic machining apparatus based on the tool schedule table set as described above is performed as follows.

In the machining of each machining center, when the machining for each tool is completed, it is determined whether the tool has reached the end of its life.
Alternatively, a determination is made as to whether or not it has been damaged. This determination is made based on, for example, whether the load current of the spindle of the machining center is within a reference range determined for each tool.

As a result of this determination, the following processing is performed. (i) If normal, this tool completion table 3 for each work
0 is set to the effect that the processing for the workpiece has been completed. (ii) When the service life has been reached or the tool has been damaged, "not yet" indicating processing incomplete is set in the tool completion table 30, and the tool is supplied from the tool stocker 16 to the machining center in order to replace the spare tool. (iii) If the service life has been reached or it has been damaged and there is no spare tool, the tool schedule table 28 is changed as described later. (iv) The fact that the tool has reached the end of its life or has been damaged is stored in a management table (not shown) for each tool.

A specific example when the tool is damaged will be described. This processing is performed according to the schedule adjusted as shown in FIG. 11 by the above-described preparation work. The duplication of the tool T6 at the level 2 is dealt with by preparing two tools T6 and enabling simultaneous use.

In such a schedule, for example, when the control unit of the FMS recognizes that the T1 (tool having a spare) of the MC2 is damaged (for example, the feed amount,
It is recognized that the spindle load deviates from the reference value),
The processing is performed as follows. a. The MC 2 is stopped, and the work is carried out of the machine using the carrier 4. As shown in FIG. 13, “unworked” indicating unworked is stored in the column of the tool T1 of the tool completion table stored for each work as to whether or not machining by each tool is completed. b. Search for a spare tool in the system and set the spare tool to M
Attach to C2. It should be noted that a tool that is frequently used or a tool corresponding to level 1 has a large effect on subsequent processes due to loss, so it is assumed that a spare tool is always provided. c. Referring to the tool schedule table of another machining center, the tool schedule of MC2 is reset as shown in FIG. 12, and the workpiece is supplied to MC2 to start machining.

As a result of the above-described processing, the processing by T1 is started with a time delay, and M1 shown in FIG.
Since the schedule of C2 overlaps with MC1 or MC3, it is necessary to reconfigure the processing of level 2. In addition, “unfinished” for T1 is rewritten to “done”, and thereafter, “done” is written in the tool completion table every time the machining of each tool is completed. Note that the tool T
Even if there is no spare, if the manned operation is in the daytime, the work can be re-input to the FMS after performing the processing corresponding to T1 using another processing machine. It is.

Next, the tools T classified into level 2
The case where 2 (a tool having no spare) is lost will be described. In the machining performed according to the tool schedule shown in FIG. 11, if the tool T2 of the MC1 is lost, the work is removed from the MC1 via the carrier 4 when the loss is found. Further, the fact that the tool T2 has been lost is written in a tool management table (not shown). Thereafter, when a new work is put into the MC1 via the carrier 4, the processing by the tool T1 is started again.

In MC2, since the machining by T2 has been completed before the loss of T2 in MC1, the machining is performed according to the same schedule as in FIG.

In the MC3, as shown in FIG. 11, since the processing by the T2 is performed after the processing of the T2 by the MC1 is completed, the processing by the T2 is skipped, and the processing by the T6 is performed immediately after the processing by the T4. Proceed to. For T3 processing at level 3,
Since T2 of level 2 is inevitable, after processing of T7,
The process of T3 is skipped and the process proceeds to T8.

That is, when the tool management table of each machining center is constantly monitored by the FMS controller 24, and there is no tool to be used next in each machining center (in the case where loss is stored).
Regardless of the tool schedule, the schedule setting is changed so that the post-process can be immediately executed without performing machining with the tool. The tool completion table 30 is constantly monitored, and the level 3 processing is executed on condition that the level 2 processing is “completed”. The setting is changed so that the next step is immediately executed without performing level 3 processing.

As described above, when the machining with some tools is omitted, the machining schedule of the tools is shifted, and if a tool that should be vacant is in use, the tool is not used. There will be a waiting time between processes of each machining center until it becomes empty.

Further, when a loss occurs in the level 3 tool, the loss of the tool is stored in the tool management table, and "not" is stored in the tool completion table. Thereafter, machining with the missing tool is omitted. That is,
Subsequent workpieces are only processed by a valid tool.

The determination as to whether or not the level 3 tool can be used can be made by the following method. That is, in the pre-machining tool table 32 that stores the tools necessary for the pre-machining for each tool, for example, “no previous tool” for T1, “T1” for T2, “T2” for T3, Number of machining tool (no previous tool if not present)
Is stored. Then, prior to machining with a predetermined tool, the machining is executed on condition that “done” is stored with reference to the main tool completion table 30 and “un”
In this case, the processing may be omitted.

As a result of the above processing, if there is no loss in the tool, the processing for all the workpieces is completed. In addition, when some of the tools are missing and there is no spare tool, the machining of the relevant tool after the occurrence of the missing and other tools that use this tool as a pre-machining tool is omitted. Work is produced. In addition, the existence of such a work having an unprocessed portion can be easily determined by checking the presence or absence of “not yet” in the tool completion table 30 after a series of automatic operations is completed.

In the above-described embodiment, a personal computer or the like provided separately from the original FMS system is used as the schedule setting unit. However, this function can be performed at the level of the main machining program, or the processing of each machining center can be performed. It is also possible to do at the level of the control device.

In the above embodiment, the tools are stored in the tool magazines of the respective machining centers and the tool stockers are provided for the entire system. However, the tool magazines of the machining centers are omitted, and a single tool stocker is used. It is also possible to adopt a method of supplying a tool to each machining center.

[0051]

As described above, according to the present invention,
When a series of machining operations are to be performed in parallel by a plurality of machining centers, simultaneous use of the same tool can be avoided by changing the tool use order and setting a tool schedule. The number of tools held as a whole can be reduced as much as possible, or the possibility of continuous operation can be increased by holding various types of tools. Further, by classifying the tools used for machining for each level and changing the use order within each level, machining requiring a plurality of tools can be performed smoothly. Furthermore, by storing whether or not machining has been completed for each tool and whether or not the tool is missing, machining that uses the tool or machining that pre-processes the tool is automatically performed after the loss occurs. Can be omitted.

[Brief description of the drawings]

FIG. 1 is a block diagram of one embodiment of the present invention.

FIG. 2 is a perspective view of a work applied to one embodiment.

FIG. 3 is a memory map diagram of a machining level table.

FIG. 4 is a timing chart of MC1 to MC3 of a tool schedule table at level 1;

FIG. 5 is a timing chart of MC1 of the tool schedule table at level 2;

FIG. 6 is a timing chart before a shift of MC2 in the tool schedule table at level 2;

FIG. 7 is a timing chart after a shift of MC2 in the tool schedule table at level 2;

FIG. 8 is a timing chart after a shift of MC3 in the tool schedule table at level 2;

FIG. 9 is a flowchart of the entire tool schedule setting process.

FIG. 10 is a flowchart of a tool schedule setting process at level 2;

FIG. 11 is a timing chart after correction of the tool schedule tables of MC1 to MC3.

FIG. 12 is a timing chart of MC2 after the occurrence of the loss of the tool of level 1;

FIG. 13 is a memory map of the tool completion table.

FIG. 14 shows MC1 to MC after the occurrence of level 2 tool breakage.
3 is a timing chart of FIG.

FIG. 15 is a schematic diagram of an FMS controlled by applying the present invention.

[Explanation of symbols]

2 Work transfer path (work transfer section) 4 Work carrier 6 Tool magazine 8 Spindle 12 Tool transfer path (tool transfer section) 14 Tool carrier 16 Tool stocker (stock section) 20 Schedule setting section 22 Main processing program 24 FMS > Controller (control unit) 26 Machining level table 27 Machining order table 28 Tool schedule table 30 Final machining completion table 32 Pre-machining tool table 36,38,4
0, 42, 44 holes MC1-MC3 Machining center (working part ) W Work

Claims (4)

(57) [Claims] 1. A plurality of processing units each including an automatic machine tool for performing machining on a work while exchanging tools according to an order set in a time series in a tool schedule table, and used in these processing units. A stock unit for storing a tool, a work transfer unit for loading or unloading a work to or from the plurality of processing units, a tool transfer unit for transferring a tool between the stock unit and the processing unit, stock unit, workpiece transfer unit, and the automatic processing system and a control unit for controlling the tool-carrying unit, a processing level table configured to store the tool and its working time to be set in the tool schedule table, each machining
A machining order table that stores the machining order of the
The pre-machining tools used for pre-machining as needed
Pre-machining tool table to be stored and each tool
The tool completion table that stores whether or not the execution has been performed is compared with the setting contents for each tool of each processing unit set in the tool schedule table, and the comparison result is displayed, and the setting contents are changed as necessary. Schedule setting part
And the control unit includes the pre-machining tool table and
And this tool completion table, and
Execute machining on condition that machining is completed,
If not completed, check the tool schedule table
An automatic machining apparatus configured to execute a process using a next tool . 2. The machining level table stores tools classified into a plurality of types, and the schedule setting unit compares setting contents of the machining order table and changes settings of the tools for each tool of each classification. The automatic processing apparatus according to claim 1, wherein: 3. The automatic machining apparatus according to claim 2, wherein the machining level table classifies the tools according to machining priorities. 4. The control unit determines whether any of the tools set in the machining order table is unusable, and if there is an unusable tool, the control unit determines the tool in the tool schedule table. The automatic processing apparatus according to any one of claims 1 to 3, wherein the processing unit is controlled so as to omit processing by a tool.