JP4806517B2 - Machining process monitoring system - Google Patents

Description

  The present invention relates to a machining process monitoring system that collects machining process information of a production facility and feeds back the collected information to a production program.

  A system that monitors the status of production equipment is a sequencer that uses information from various detectors, such as input signals from sensors and alarm signals, as well as information from numerical control units, among information related to control of production equipment. Via a network to a remote monitoring PC or monitoring server.

  Monitoring PCs and monitoring servers use general-purpose SCADA (Supervisory Control and Data Acquisition) software to graphically display the operating status of equipment, analyze the operating time of equipment, and grasp the number of productions.

  It also has facilities maintenance and other functions such as cause analysis of equipment abnormalities and alarms, and failure history analysis.

  In addition, in order to increase the efficiency of the prototype process, the data at the time of machining the prototype part is transmitted to the host computer and compared with the CAD data to obtain improvement information in the machining process so that the dimensions and shape of the part are appropriately performed. The technique is described in Patent Document 1.

JP 2003-271111 A

  However, in the conventional technology, although it is possible to set the processing conditions for processing the workpiece to an appropriate size and shape, the processing conditions for improving the productivity after processing to an appropriate size and shape are possible. The feedback is not taken into consideration at all.

  As an approach to improve productivity, a method of obtaining the machining condition value of the machining program necessary for production with a simulator is also conceivable, but it can be applied to actual machining due to differences in the processing equipment used and the usage environment, and It is difficult to derive machining condition values with higher production efficiency. Currently, the operator often uses the five senses, such as visual inspection, to check the machining status and adjust the machining conditions such as the feed rate and spindle speed while machining with the actual machine.

  In particular, this adjustment work requires skill, so skilled operators are indispensable to improve productivity. The recent drastic decrease in skilled operators aims to improve productivity and pass on skills. It is a big issue above.

  Therefore, as one method for improving the production efficiency in a production shop that uses many NC machines, means for automatically obtaining information indicating the state of the equipment from the production equipment is used. A method is conceivable in which machining condition data that is considered to be highly productive is found, and the found specification values are redefined for the original NC program.

  In this case, it is necessary to link the machining process information stored in the monitoring server and indicating the state of the equipment currently being machined or the machining status and the NC program used for the actual machining.

  However, although it is possible to specify the data start position by the machining start time or the machining start switch operation record, etc., when there is no information indicating the NC program transition in the machining process information, the machining process information and the NC program completely Linking is difficult.

  Even if machining process information includes information indicating the transition of the NC program, the amount of data is large, and machining process information is represented in hexadecimal or binary code, so that code conversion is required. Furthermore, the work of associating the subsequent machining process information with the NC program is very complicated.

  In addition, it takes time to extract and compare multiple machining condition data such as feed speed and spindle rotation speed, and to feed back the results to the CAD / CAM system. In reality, it was difficult to generate an NC program from machining process information.

  Furthermore, in order to extract highly efficient processing condition data, such as when there is no means to automatically acquire information indicating the state of equipment from production equipment, skilled operators etc. check the status during processing in detail. A method of recording the processing condition values considered to be the best on paper or the like can be considered.

  In this case, however, a recording staff is required in addition to the operator, and the labor cost is doubled.

  In addition, it is difficult to record machining condition values that are completely linked to the machining process, and it is also difficult to record completely with a video camera that does not require a recording staff. .

  An object of the present invention is to realize a machining process monitoring system that is capable of selecting and reproducing a machining condition setting value that is optimal for improving productivity and that is selected by a skilled worker.

  According to the present invention, the skilled worker sets machining setting conditions (conditions determined by the characteristics of each device, the usage environment, etc.) that cannot be set by the machining conditions of the machining program at the initial setting. In order to compare the initial machining conditions with each other, the two machining conditions are displayed in correspondence with the transition of the NC program.

  Then, the two machining conditions are compared, a machining condition with high production machining efficiency is selected, and the NC program is corrected so as to satisfy the condition. Thereafter, if machining is performed in accordance with the modified NC program, highly efficient machining can be performed without depending on a skilled person.

That is, the present invention is configured as follows to achieve the above object.
(1) Machining process information including machining performance data obtained by machining a workpiece with actual production equipment using an NC program, during which the operator uses the characteristics and use of each device during machining. Extracting machining conditions with high production machining efficiency based on machining process information including machining conditions set in consideration of environmental conditions, and generating NC programs with high production machining efficiency by feeding back to machining information of CAD / CAM means A machining process monitoring system
And information acquisition means to gather the machining process information transmitted from a control device of the machining at the same time as the production equipment of the workpiece in the actual production facilities,
A storage medium for storing initial machining information including a plurality of initial machining conditions used for generating the NC program, and storing the machining process information;
The initial machining conditions included in the initial machining information stored in the storage medium are compared with the machining conditions included in the accumulated machining process information , and the initial machining conditions and machining included in the machining process information are compared. Data comparison means for selecting the machining conditions included in the machining process information when the conditions are different and the machining conditions included in the machining process information are machining conditions having higher production machining efficiency than the initial machining conditions ;
Based on the processing conditions included in the machining process information selected by said data comparing means, and CAD / CAM unit for correcting the NC program,
Processing information based on the NC program which is corrected by the CAD / CAM unit and an information transmitting means for transmitting the information to the control unit of the production equipment.

  (2) Preferably, in the above (1), the control device of the production facility, the information collecting means and the information transmitting means are connected through an electric communication line capable of bidirectional communication.

(3) Machining process information including machining performance data obtained by machining a workpiece with actual production equipment using the NC program, and the operator can identify the characteristics and use of each device during machining using the NC program. Production facility control means for transmitting machining process information including machining conditions set in consideration of environmental conditions through the transmission means simultaneously with the processing of the workpiece in the actual production equipment ,
Processing information collecting means for collecting processing information transmitted from the production equipment control means simultaneously with processing of the workpiece in the actual production equipment ;
Machining information storage means for storing initial machining information including a plurality of initial machining conditions used for generating the NC program, and storing machining process information collected by the machining information collecting means;
Display means for displaying the comparison information for comparing the said initial machining conditions included in the processing conditions and the initial processing information included in the processing information the machining process information stored in the storage means with each other,
Machining conditions determined based on the contrast information displayed on the display means, wherein the initial machining conditions and the machining conditions included in the machining process information are different, and the machining conditions included in the machining process information are the initial conditions. Correction processing means for correcting the NC program according to the machining conditions included in the machining process information when the machining conditions have higher production machining efficiency than the machining conditions ;
The NC program is corrected by the correction processing unit to the production equipment control means, and a data transmission means for transmitting via a transmission means.

  (4) Preferably, in the above (3), the production facility control means, the processing information collection means and the data transmission means are connected through an electric communication line capable of bidirectional communication.

  It is possible to realize a machining process monitoring system that can select and reproduce the machining condition setting value of an expert who is optimal for improving productivity.

  Also, by feeding back machining condition data obtained from production equipment operated by skilled operators to the NC program, a highly productive NC program capable of high-efficiency machining that does not require skill is generated and provided. be able to.

Embodiments of the present invention will be described below with reference to the accompanying drawings.
FIG. 1 is an overall configuration diagram of a machining process monitoring system according to an embodiment of the present invention. The machining process monitoring system of the present invention uses an intranet to share a machining process information, machining information, and NC program server between the monitoring target production facility and the machining process monitoring system, thereby enabling a relatively inexpensive system. Realized.

The processing process monitoring system shown in FIG. 1 collects various types of information about the monitoring target production facility 102 and the equipment in the monitoring target production facility 102 via the intranet, and extracts highly efficient processing condition data from the processing process information. A machining process monitoring system 100 to be managed and a CAD / CAM system 101 connected to the machining process monitoring system 100 are provided.

  The monitoring target production facility 102 includes an operation panel 17 for operating the production facility, a sensor 18 that detects the presence or absence of a processing target, an actuator 16 that performs a processing operation, and a PLC (programmable controller) that controls input / output. Unit 1, a servo motor 15, and a numerical control unit 14 that controls the servo motor 15.

  Note that the configuration of the monitoring target production facility 102 may include either the PLC unit 1 or the numerical control unit 14, or may be a facility that includes a sequence circuit that combines a relay.

  The machining process monitoring system 100 is connected to the monitoring target facility 102 via the transmission path a, and transmits the machining process information from the PLC unit 1 of the monitoring target facility 102 to the information collecting base station 3 via the information collecting slave station 2. To do. Note that the transmission line a is usually a wired type, but a wireless type can be used for production facilities where wiring is difficult.

  The information collection base station 3 is preferably arranged in units of production shops or areas. Further, the machining process monitoring system 100 includes a plurality of information collecting base stations 3, and further includes a plurality of information collecting slave stations 2 for one base station.

Further, machining process monitoring system 100 includes a processing information DB (Data Base) 6, which is a storage medium for storing a machining process information once stored in the information collection base station memory (not shown) at any time, at a specified interval, A data comparison unit 4 is provided for performing processing for comparing the processing process information and the original NC program from the processing information DB 6 and comparison processing.

Further, the machining process monitoring system 100 includes a correction processing unit 5 that modifies machining information of the original NC program, and a machining information reading unit 7 for passing the machining information 8 to the CAD / CAM system 101.

Furthermore, the machining process monitoring system 100 transfers the NC program 11 generated by the CAD / CAM system to the machining information DB 6 and transfers the NC program to the numerical control unit 14 of the monitoring target equipment 102. And a data transmission unit 13 for performing the above.

  Here, the machining process information is obtained via the PLC unit 1 and input signals from the operation panel 17 and the sensor 18 to which machining conditions and the like are input by the operator 19, and output signals from the actuator 16, Information from the numerical controller 14 such as the load current value of the axis, the program number being called, the program line number being executed, the M code number being executed, the alarm number, etc., or a temperature sensor externally attached to the monitoring target equipment not shown Also, the load current measurement CT sensor, the analog input value from the vibration sensor, and the machining performance of the workpiece (the machining amount or quantity per unit time). The information collecting slave station 2 can collect the processing process information described above.

The information collection base station 3 has a function of instructing information collection timing setting and information designation for the information collection slave station 2, and the collected information is a file in which a date and a symbol indicating information content are combined. A name is added and periodically transferred to the processing information DB 6.

  The information collection slave station 2 may collect information periodically, at the time when the input signal from the PLC unit 1 is input, or when the control signal from the machining process monitoring system 100 is output. It can also be.

  In addition, in order to designate information to be acquired, for example, a memory address in the information collecting base station 3 is designated based on a memory map 200 as shown in FIG. When information to be acquired and an acquisition timing are determined and information collection is started, the information collection base station 3 acquires processing process information from the connected information collection slave station 2.

These settings for the information collection base station 3 can all be performed remotely from a PC or the like connected to the transmission line b, so there is no need to go to the installation site. Further, as shown in FIG. 3, the information collection base station 3 transfers information processing equipment 301, a wireless unit 302, a wired connection terminal block 304, collected processing process information, and sets collection conditions. LAN connection port 305 for connecting to a PC.

The information collecting base station 3 includes an AC 100V power source and a power supply 306 for converting AC 100V into DC 24V, and these are housed in a box 300.

  This is because standardization is achieved by storing only devices that do not depend on the form of the production facility 102 to be monitored in one compact unit, thereby realizing cost reduction and installation cost reduction.

  Even when temporary process monitoring is required, since it is relatively easy to carry and equipped with the wireless unit 302, if a wireless unit is installed in the slave station 2, wiring is not required and installation is easy. It is valid.

  The main information handled by the machining process monitoring system 100 is managed by the machining information DB 6, and as shown in FIG. 4, the machining process information 401 transferred from the information base slave station 2 is data in text format, and the content is Expressed in hexadecimal.

Further, the machining information 402 includes contents from a machining plan / instruction to CAD / CAM and NC data. Further, the NC program 403 is data after the machining definition data is converted into NC format specifications for each machine.

  Further, as peripheral functions of the machining information DB 6, a data comparison unit 4 that compares the machining process information 401 and the machining information 402, a correction processing unit 5 that corrects the result after comparison as new machining information, and the machining information 402. The machining information reading unit 7 for passing to the CAD / CAM system 101, the information writing unit 12 for writing the NC program generated by the CAD / CAM system 101 to the machining information DB 6, and the NC program monitored from the machining information DB 6 There is a data transmission unit 13 for transmission to the target facility 102. These peripheral functions of the processing information DB 6 are software, and are installed in one or a plurality of PCs and used for processing data stored in the processing information DB 6.

  The data comparison unit 4 also acquires machining process information 401 indicating the actual machining process status obtained from the information collection base station 3 such as the execution number of the NC program, time information when the program is used, and the machining process information. The machining information 402 of the NC program used for machining for which 401 is obtained is graphically displayed. By the display by the data comparison unit 4, the machining process information 401 and the machining information 402 can be compared.

  The machining process information 401 records the executed NC program number, and the machining information 402 also records the NC program number in advance. Since the NC program number is a unique number, it becomes a keyword that links both data.

  In addition to the NC program number, this keyword may be a combination of date, equipment name, serial number, alphabet, and the like.

  Further, the machining process information 401 is expressed in hexadecimal numbers, and is expanded into binary numbers once and converted into decimal machining condition data according to the memory map 200 shown in FIG. 2 for easy understanding by humans. To do. This makes it easy to compare the machining process information 401 and the machining information 402.

  The comparison operation between the machining process information 401 and the machining information 402 is performed by displaying the NC program on the left side of the screen as shown in the display screen 103 shown in FIG. 5 and the comparison target selected from the pull-down menu on the PC screen on the right side. The original data (broken line) of the data and the machining result data (solid line) by the expert are superimposed and displayed in a graph. At this time, the original data and the processing result data may be separately arranged and displayed without overlapping.

  Furthermore, the deviation amount between the original data and the machining result data is graphically displayed on the right side of the screen so that a person can see and intuitively compare it, and the data is displayed in units or ratios of the target data.

  The comparison target data is, for example, a feed speed, a feed speed override value, a spindle load current value, a vibration value, an air temperature, a workpiece temperature, a sound pressure level, and the like. The example shown in FIG. 5 is an example when the feed speed is selected as the comparison target data, and other comparison data can also be selected.

  In addition, by accumulating the processing data of new operators, it is possible to compare the results data of skilled workers with the results data of new operators, so that the difference in skills can be shown quantitatively. Can also be used.

  In addition, from the viewpoint of safety, the above-described comparison work is performed once by a person to confirm the machining condition value. However, a method that employs a higher condition value or a method that uses all skilled operator condition values. An automatic comparison method is also possible.

  The comparison work by humans is performed in units of NC program lines, and the values are adjusted while checking the feed rate value and feed rate override value on the screen. The value may be the original data or may be actual data.

  Furthermore, a value between them or any other value can be set.

  When the comparison work is completed, the correction end button 103A on the screen is pressed, and the processing result data is passed to the correction processing unit 5.

  The correction processing unit 5 rewrites the processing information such as the feed speed value and the feed speed override value based on the result of the data comparison section 4. At this time, a unique number such as an NC program number for identifying the machining information, the number of corrections, and the correction date are also recorded in the machining information.

  Thereby, when this data is used and a trouble occurs, it is possible to facilitate data tracking investigation. After rewriting is completed, it is stored in the processing information DB 6.

  The machining information 402 stored in the machining information DB 6 includes information including a machining plan / instruction, CAD / CAM, and NC data. Based on this information, the CAD / CAM system 101 generates the NC program 11.

  At this time, means for transferring the processing information 402 to the CAD / CAM system 101 is the processing information reading unit 7. The machining information reading unit 7 is customized to smoothly pass data to the CAD / CAM 101 and serves as an interface with the machining process monitoring system 100.

  In the above-described example, the machining information reading unit 7 is in the machining process monitoring system 100, and the execution operation is also performed from the machining process monitoring system 100, converted into data in a format that matches the target CAD / CAM system 101, and the target CAD This is an example of transferring to the database of the / CAM system 101.

  The present invention is not limited to the above-described example, but can be applied to an example in which the machining information reading unit 7 adds in to the CAD / CAM system 101 side and performs an execution operation from the CAD / CAM system 101 side.

  As the initial machining information, a value that has been studied on the desk such as an actual performance value is set, and the NC program 11 can be generated by the CAD / CAM system 101 even when there is no machining process information 401.

  The NC program 11 generated based on the initial machining information having no machining record is temporarily stored in the machining information DB 6 by the information writing unit 12. This information writing unit 12 may be independent software independent of the machining process monitoring system 100.

  When machining is performed using the NC program stored in the machining information DB 6, machining process information is simultaneously collected in the machining information DB 6 from the PLC unit 1 of the target facility 102 via the information collection slave station 2 and the information collection base station 3. It is done.

  Then, the data extracted as the machining process information by the data comparison unit 4 or the correction processing unit 5 is created as machining information in which the high-efficiency machining conditions are redefined. Based on the created machining information, an NC program 11 is generated by the CAD / CAM system 101 and is temporarily stored in the machining information DB 6 in the same manner as described above.

  The NC program 11 generated by the CAD / CAM system 101 is transferred to the numerical control unit 14 of the monitoring target equipment 102 by the data transmission unit 13. The data transmission unit 13 may use commercially available data transfer software.

  As described above, according to the present invention, the machining setting conditions of an expert who cannot be set with the machining conditions of the machining program at the time of initial setting (conditions determined by the characteristics of each device, the usage environment, etc.) Is obtained by setting the condition of an actual expert, and this is stored, and both machining conditions are displayed in correspondence with the transition of the NC program for comparison with the initial machining conditions.

  Then, the two machining conditions are compared, a machining condition with high production machining efficiency is selected, and the NC program is corrected so as to satisfy the condition. Thereafter, if machining is performed in accordance with the modified NC program, highly efficient machining can be performed without depending on a skilled person.

The processing process monitoring system 100, the CAD / CAM system 101, and the monitoring target production facility 102 can be applied not only when they are arranged in the same factory, but only the monitoring target production facility 100 is included in the factory. Yes, the machining process monitoring system 100 and the CAD / CAM system 101 may be located at other locations not within the factory.

Further, a single machining process monitoring system 100 and a CAD / CAM system 101 are connected to a plurality of production facilities 100 to be monitored through an electric communication line capable of two-way communication such as the Internet to correct machining conditions, etc. Can also be done.

1 is a schematic configuration diagram of a machining process monitoring system according to an embodiment of the present invention. 4 is a table showing the contents of each bit by expanding the machining process information of hexadecimal number into binary number in one embodiment of the present invention. It is an apparatus block diagram of an information collection base station. It is a figure which shows the information handled by process information DB. It is a figure which shows an example of the display screen which shows the processing condition in a data comparison part.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 PLC part 2 Information collection slave station 3 Information collection base station 4 Data comparison part 5 Correction process part 6 Processing information DB
7 Machining Information Reading Unit 8 Machining Information 11 NC Program 12 Information Writing Unit 13 Data Transmitting Unit 14 Numerical Control Unit 15 Servo Motor 16 Actuator 17 Operation Panel 18 Sensor 19 Operator 100 Machining Process Monitoring System 101 CAD / CAM System 102 Monitored Equipment DESCRIPTION OF SYMBOLS 103 Display screen 300 Box 301 Collection apparatus 302 Wireless unit 303 Branch stand 304 Wired connection terminal block 305 LAN connection port 306 Power supply 401 Machining process information 402 Machining information 403 NC program

Claims (4)

Machining process information that includes machining performance data obtained by machining workpieces with actual production equipment using NC programs. During machining by the NC program, the operator can check the characteristics and operating environment of each device. Machining process that generates NC program with high production machining efficiency by extracting machining conditions with high production machining efficiency based on machining process information including machining conditions set in consideration and feeding back to machining information of CAD / CAM means A monitoring system,
And information acquisition means to gather the machining process information transmitted from a control device of the machining at the same time as the production equipment of the workpiece in the actual production facilities,
A storage medium for storing initial machining information including a plurality of initial machining conditions used for generating the NC program, and storing the machining process information;
The initial machining conditions included in the initial machining information stored in the storage medium are compared with the machining conditions included in the accumulated machining process information , and the initial machining conditions and machining included in the machining process information are compared. Data comparison means for selecting the machining conditions included in the machining process information when the conditions are different and the machining conditions included in the machining process information are machining conditions having higher production machining efficiency than the initial machining conditions ;
Based on the processing conditions included in the machining process information selected by said data comparing means, and CAD / CAM unit for correcting the NC program,
Working process monitoring system characterized in that it comprises a communication means for processing information based on the NC program which is corrected by the CAD / CAM unit for transmitting the information to the control unit of the production equipment.   2. The machining process monitoring system according to claim 1, wherein the production equipment control device, the information collecting means and the information transmitting means are connected through an electric communication line capable of bidirectional communication. . Machining process information that includes machining performance data obtained by machining workpieces with actual production equipment using NC programs. During machining by the NC program, the operator can check the characteristics and operating environment of each device. Production equipment control means for transmitting machining process information including machining conditions set in consideration of the workpieces in the actual production equipment simultaneously with the transmission means,
Processing information collecting means for collecting processing information transmitted from the production equipment control means simultaneously with processing of the workpiece in the actual production equipment ;
Machining information storage means for storing initial machining information including a plurality of initial machining conditions used for generating the NC program, and storing machining process information collected by the machining information collecting means;
Display means for displaying the comparison information for comparing the said initial machining conditions included in the processing conditions and the initial processing information included in the processing information the machining process information stored in the storage means with each other,
Machining conditions determined based on the contrast information displayed on the display means, wherein the initial machining conditions and the machining conditions included in the machining process information are different, and the machining conditions included in the machining process information are the initial conditions. Correction processing means for correcting the NC program according to the machining conditions included in the machining process information when the machining conditions have higher production machining efficiency than the machining conditions ;
Working process monitoring system, characterized in that the NC program which is corrected by the correction processing unit to the production equipment control means, and a data transmission means for transmitting via a transmission means.   4. The machining process monitoring system according to claim 3, wherein the production facility control means, the machining information collection means, and the data transmission means are connected through an electric communication line capable of bidirectional communication. system.

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