JP3543147B2 - Machine tool abnormality management device - Google Patents

Description

[0001]
TECHNICAL FIELD OF THE INVENTION
BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a machine tool abnormality management device capable of recording and reproducing an image of a machine tool and an operating condition of the machine tool when an abnormality occurs in the machine tool.
[0002]
[Prior art]
In a conventional machine tool, when an error occurs in the machine tool, after the machine tool is stopped by an alarm, the state of the work being processed, the state of the tool present in the machining area, the state of the tool, and the The operating state of the machine tool at the time of occurrence of the error is checked to determine the cause.
[0003]
[Problems to be solved by the invention]
However, after the machine tool is stopped by the alarm, the work state at the time of occurrence of the abnormality and the actual operating state of the machine tool are lost, so judgment based on the experience of the worker is an important factor. . In this case, it is impossible for an inexperienced worker to find out the proper cause, and there is a problem that it is difficult to take appropriate measures after the alarm.
[0004]
Therefore, it is conceivable to collect an image of the machine tool when an abnormality occurs, and to reproduce the image after an alarm occurs, so that it is easy to find the cause. Simply collecting and regenerating takes a lot of time and effort to find the cause.
[0005]
In view of the above circumstances, the present invention relates to a machine tool capable of recording an operation image of a machine tool and operation data of the machine tool at that time in association with each other when an abnormality occurs, and reproducing them as needed. It is an object to provide an abnormality management device.
[0006]
[Means for Solving the Problems]
The invention according to claim 1 is a machine tool (1) driven and controlled by an NC device (22),
A plurality of cameras (10) having an imaging area of a machining area (ARA) of the machine tool and a movable part of the machine,
An image data generation unit (12) connected to the camera and configured to generate image data (DT1) for each predetermined sampling time from an image captured by the camera;
Operating data acquisition means (16) for acquiring, from the NC device, an operation state of the machine tool at every predetermined sampling time as operation data;
An operation record that combines the image data generated by the image data generation unit and operation data corresponding to the image data, and synthesizes an operation record (PC) at a certain point in time for each of the machining area and the machine movable part. Synthesis means (16),
An image file (15) for storing the operation record synthesized by the operation record synthesis means,
An abnormality detection unit that detects an abnormality of the machine tool and outputs an abnormality detection signal including information indicating a portion where the abnormality has occurred;
An abnormal part determination unit that analyzes an abnormality detection signal from the abnormality detection unit and determines in which part of the machine tool the abnormality has occurred;
File storage means for storing the operation record regarding the part of the machine tool in which the abnormality has occurred, determined in the abnormal part determination means, in a separate file in the image file,
Means for inputting an image reproduction command,
When the image reproduction command is input from the input unit, the image reproduction unit (17) reproduces an operation record related to the abnormal part stored in the separate file .
[0007]
The invention according to claim 2 is characterized in that the image file always stores the operation record (PC) for the latest predetermined time (for example, the latest two to three minutes).
[0008]
The invention according to claim 3 is characterized in that the operation record (PC) has image data that captures a processing state of the work (6) in the processing area,
The operation data corresponding to the image data is constituted by actual processing data (D1 to D10, etc.) of the machine tool processing the workpiece at the time of acquiring the image data.
[0009]
A fourth aspect of the present invention, provided the external input means image transmission request via the communication line (23) (C2) is that will be input from the outside of the machine tool (21),
Wherein when the there is an image transmission request from the outside of the machine tool, and transmits the stored driving record in the image file to an external of said machine tool to which the image transmission request is output, driving record transmission Means (13, 17) are provided.
[0010]
The invention of claim 5 is characterized in that the operation record synthesizing means records the operation data as binary data when synthesizing the operation records.
[0011]
【The invention's effect】
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 the machine tool at the time of sampling of the image are generated and stored, is stored in the machine tool. When an abnormality occurs, the cause can be quickly and accurately determined by reproducing the operation record.
[0012]
According to the invention of claim 2, when the abnormality occurs in the machine tool, the necessary information is the state of the machine tool near the time of occurrence of the abnormality, so that an appropriate operation record storing operation can be performed with a small memory capacity. Become.
[0013]
According to a third aspect of the present invention, an abnormality related to machining of a work, which frequently occurs, is accurately determined based on an operation record in which a machining state of the work and actual machining data of the machine tool machining the work are combined. I can do it.
[0014]
According to the invention of claim 4, since the operation record of the machine tool can be acquired from the outside, it is easy to find out the cause of the abnormality at a service center or the like away from the installation place of the machine tool, and to quickly respond to the abnormality. Response is possible.
[0015]
According to the fifth aspect of the present invention, since the operation data is recorded as binary data, it is possible to easily reproduce the state in which the abnormality has occurred by simulation or the like using the operation data, and to investigate the cause of the abnormality. It can be done quickly and accurately.
[0016]
Note that the numbers in parentheses are for convenience showing the corresponding elements in the drawings, and therefore, the description is not limited to the description on the drawings.
[0017]
BEST MODE FOR CARRYING OUT THE INVENTION
Hereinafter, embodiments of the present invention will be described with reference to the drawings.
[0018]
FIG. 1 is a block diagram illustrating an example of a machine tool abnormality management device to which the present invention is applied, and FIG. 2 is a diagram illustrating an example of an operation record.
[0019]
As shown in FIG. 1, the machine tool 1 has a frame 2, and a main shaft 5 on which a chuck 3 is mounted is provided on the frame 2 so as to be rotatable about a Z axis. A work 6 to be machined is held by the chuck 3, and a tool rest 7 is movable on the frame 2 in the X-axis and Y-axis directions perpendicular to the Z-axis, and is centered on the Y-axis. And is provided so that it can be rotationally driven and positioned in the direction of arrow B. A tool 9 such as a rotary tool or a turning tool is provided on the tool rest 7 so as to be detachable and rotatable in the direction of arrow A when the rotary tool is mounted.
[0020]
The frame 2 is provided with a CCD camera 10 that covers a space in which machining of a workpiece can be performed by a machine tool, that is, a processing area ARA as an imaging range thereof. A CCD camera is arranged in such a manner that an area where an abnormality frequently occurs in a movable part of a machine such as a tool changing device or a tool storage device is set as an imaging range.
[0021]
The CCD camera 10 is connected to an image recording control unit 12 constituting an abnormality management device 11. The abnormality management device 11 is connected to the main control unit 13 via the bus line 14. In addition to the unit 12, an image file 15, an image editing unit 16, an alarm image reproducing unit 17, an alarm detecting unit 19, a display 20, a communication control unit 21, and the like are connected.
[0022]
The image editing unit 16 is connected to an NC device 22 that drives and controls each control axis of the machine tool 1 and an auxiliary machine. The NC device 22 and the abnormality management device 11 are externally integrated with the frame 2. It is embedded and arranged. Note that the NC device 22 and the abnormality management device 11 do not necessarily have to be incorporated and arranged so as to be apparently integrated, and may be arranged separately.
[0023]
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.
[0024]
Since the machine tool 1 and the like have the above-described configuration, the processing by the machine tool 1 is performed by the NC device 22 not shown in the state where the workpiece 6 to be machined is held on the chuck 3 as shown in FIG. By appropriately driving the spindle 5 and the tool rest 7 in accordance with the machining program stored in the memory, predetermined machining is performed by the tool 9 mounted on the tool rest 7.
[0025]
When processing of the workpiece 6 by the NC device 22 is started, a processing start signal S1 is output to the main control unit 13 via the image editing unit 16 of the abnormality management device 11, and the main control unit 13 receives the signal. The image recording control unit 12 is instructed to capture an image of the operating state of the machine tool by the CCD camera 10, particularly, the processing state of the work in the processing area ARA.
[0026]
The image recording control unit 12 drives the plurality of CCD cameras 10 to capture the operation status 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 to capture the image of the work 6 in the processing area ARA. The processing status is also captured as an image. The image captured in this manner is sampled at predetermined time intervals by the image recording control unit 12 and output to the image editing unit 16 as image data DT1.
[0027]
The image editing unit 16 synchronizes with the sampling time of the image data DT1 in the image recording control unit 12 and synchronizes the operating conditions of the machine tool at that time, that is, the rotational speed of the main spindle, the feed speed, and the tool edge. The coordinate position, the C-axis positioning angle of the main shaft, the load (load) ratio of each axis at that time, and other data important for the operation of the machine tool and the machining of the work are acquired as operation data DT2.
[0028]
The image editing unit 16 combines the image data DT1 sent from the image recording control unit 12 and the operation data DT2 acquired from the NC device 22 at that time, and records the image data DT1 in the image file 15 as an operation record PC.
[0029]
As shown in FIG. 2, the operation record PC is formed such that the image data DT1 at the same sampling time and the operation data DT2 of the corresponding machine tool corresponding to the image are combined in one frame FM. For example, in the operation record PC shown in FIG. 2, the image data DT1 is an image in which the machining state of the work 6 in the machining area ARA is captured, and the operation data DT2 is the tool spindle speed at that time (the captured spindle speed). Since the processing indicated by the image data DT1 is processing by a rotary tool, the number of rotations of the rotary tool mounted on the tool rest 7 is recorded.) D1, feed speed D2, X-axis coordinate position D3, Y-axis coordinate position D4, The sun coordinates such as Z-axis coordinate position D5, C-axis positioning angle D6, tool spindle load ratio D7, X-feed shaft load ratio D8, Y-feed shaft load ratio D9, and Z-feed shaft load ratio D10. It is actual machining data (not a value specified on the machining program) that the machine tool is machining the work 6 at the time of the ring, and the image data DT1 and the operation data DT2 are stored and recorded in the same frame FM. ing.
[0030]
The operation data DT2 is recorded in the frame FM in a binary format, but may be stored in the frame FM in the form of image information. The operation data DT2 is stored in a binary format, which is convenient because the operation data DT2 can be used as it is to perform a simulation or the like when investigating the cause of the abnormality later.
[0031]
Therefore, by referring to the frame FM, the machining state of the work 6 and the operating state of the machine tool at a certain point in time can be immediately determined. The operation record PC is generated not only for the image data DT1 captured by the CCD camera provided for capturing the processing area ARA, but also for the image data DT1 captured by the CCD camera provided at another position. In this case, the operation data DT2 related to the image recorded by the image data DT1 is combined with the operation data DT2 combined in the same frame FM. For example, when the image data DT1 relates to a tool changer, the operation data DT2 is also synthesized with various operation / control data for the tool changer.
[0032]
In this manner, the video sent from each CCD camera is synthesized by the image editing unit 16 as an operation record PC in which the image data DT1 and the operation data DT2 corresponding to the image data DT1 are synthesized at a predetermined sampling time, and sequentially added to the image file 15. Go stored. The operation record PC stored in the image file 15 is sequentially stored in the image editing unit 16 by the image editing unit 16 at the sampling time. In the image file 15, the operation record PC is output from the image editing unit 16. The operation record PC is stored for the latest two to three minutes, and the old operation record PC before that is discarded every time a new operation record PC is input. Therefore, the latest operation record PC is always stored in the image file 15 for a predetermined time.
[0033]
In this way, the machining of the workpiece 6 of the machine tool 1 is performed. If an abnormality occurs in the operation of the machine tool 1 for any reason, the NC device 22 detects the abnormality and immediately starts the operation of the machine tool. At the same time, the abnormality detection signal S2 is output to the main control unit 12 via the alarm detection unit 19. When the abnormality detection signal S2 from the NC device 22 is input, the main control unit 12 stops the image capturing operation and the operation recording PC generation operation for the image recording control unit 12 and the image editing unit 16 after a predetermined time. At the same 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 a part where the abnormality has occurred, it can be easily determined in which part of the machine tool 1 the abnormality has occurred.
[0034]
Next, the main control unit 12 instructs the alarm image reproduction unit 17 to store the operation record PC relating to the part where the abnormality of the machine tool has occurred up to the point when the abnormality detection signal S2 is input. In response to this, the alarm image reproducing unit 17 stores the operation record PC recording the image of the corresponding part in another file.
[0035]
The operator inputs the image reproduction command C1 to the alarm image reproduction unit 17 via the main control unit 12 to determine the cause of the abnormality from an appropriate input unit such as a keyboard, and receives the alarm image C1. The reproduction unit 17 reproduces, on the display 20, the operation record PC related to the part where the abnormality of the machine tool has occurred, which is stored in another file. As described above, the operation record PC stores the operation data such as the current position and the load of the image data DT1 and the machine tool corresponding to the image data DT1 for a predetermined time immediately before the occurrence of the abnormality, that is, the straight line 2-3 minutes. Since the data DT2 is continuously recorded at a predetermined sampling time (for example, every one second) in a synthesized form, by reproducing them on the display 20, the vicinity of the time when the abnormality occurs, By accurately grasping the behavior of the machine tool and analyzing the operation data DT2 stored in a binary format, it becomes easy to analyze an abnormal state and to respond to it.
[0036]
The operation record PC can be transmitted from outside to the outside via the communication line 23. That is, when an image transmission request C2 is input from an external service center 25 or the like via the communication line 23 to the communication control unit 21, the main control unit 12 instructs the alarm image reproduction unit 17 to operate the corresponding operation in which the abnormality has occurred. Command transmission of the recording PC. Upon receiving this, the alarm image reproducing unit 17 immediately outputs the corresponding operation record 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 record PC. It verifies the behavior of the machine tool in the vicinity of the time when the abnormality has occurred, and helps to find the cause.
[0037]
The machine tool to which the abnormality management device 11 is mounted is not limited to a lathe as shown in FIG. 1, but may be any machine tool such as a machining center or a milling machine.
[Brief description of 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.
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 means, image transmitting means (alarm image reproducing section)
21 ... external input means (communication control unit)
22 NC device 23 Communication line C2 Image transmission request PC Operation record D1 to D10 Processing data

Claims (5)

In a machine tool driven and controlled by an NC device,
A plurality of cameras, with a processing area and a machine movable portion of the machine tool as an imaging range,
An image data generation unit connected to the camera, which generates image data for each predetermined sampling time from an image captured by the camera,
Operating data acquisition means for acquiring, from the NC device, an operation state of the machine tool at every predetermined sampling time as operation data;
An operation record synthesis unit that synthesizes image data generated by the image data generation unit and operation data corresponding to the image data, and synthesizes an operation record at a certain point in time for each of the machining area and the machine movable part ;
An image file for storing the operation record synthesized by the operation record synthesis means,
Abnormality detection means for detecting an abnormality of the machine tool and outputting an abnormality detection signal including information indicating a portion where the abnormality has occurred;
An abnormal part determination unit that analyzes an abnormality detection signal from the abnormality detection unit and determines in which part of the machine tool the abnormality has occurred;
File storage means for storing the operation record regarding the part of the machine tool in which the abnormality has occurred, determined in the abnormal part determination means, in another file in the image file,
Means for inputting an image reproduction command, and
When the image reproduction command is input from the input unit, an image reproduction unit that reproduces an operation record related to the portion where the abnormality has occurred stored in the separate file .
Machine tool abnormality management device. 2. The machine tool abnormality management device 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 capturing a processing state of the work in the processing area,
The machine tool abnormality management device according to claim 1, wherein the operation data corresponding to the image data is actual machining data of the machine tool machining the workpiece at the time of acquiring the image data. External input means for image transmission request via the communication line are entered from the outside of the machine tool is provided,
Wherein when there is an image transmission request from the outside of the machine tool, and transmits the stored driving record in the image file to an external of said machine tool to which the image transmission request is output, driving record transmitting means The abnormality management device for a machine tool according to claim 1, wherein the abnormality management device comprises: The machine tool abnormality management device according to claim 1, wherein the operation record synthesizing unit records the operation data as binary data when synthesizing the operation records.

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