JP6174208B2 - Sim production method - Google Patents

Description

The present invention relates to a technique for manufacturing a shim that is inserted into a gap in order to fill a gap between two members assembled to each other.

  At an assembly site where a single structural body (for example, an aircraft fuselage or wing part) is assembled from a plurality of members, an unexpected gap occurs between the two members assembled together due to manufacturing variations of the members. May end up. In this case, if the unscheduled gap is left unattended, an unscheduled relative displacement will occur between the two members separating the gap.

  In order to prevent such a situation, an operation for filling the gap is performed by inserting a shim into the gap. In this work, prior to the insertion of the shim into the gap, the work of measuring the thickness of the gap using a gap gauge or the like and the work of adjusting the thickness of the shim to match the thickness are performed. Is called.

  As this kind of shim, for example, a solid shim composed of a single layer or a laminate shim in which a plurality of layers are peeled from each other (also referred to as “multi-layer shim” in the industry), etc. Exists. In Patent Documents 1 and 2, as conventional examples of this type of shim, a shim made of a thin plate such as a titanium plate or an aluminum plate (an example of the solid shim), a shim made of a flat plate made of a composite material (an example of the solid shim) ), A laminate shim in which each layer is made of aluminum, and a laminate shim in which each layer is made of a composite material.

  Conventionally, when using a solid shim, prior to inserting the solid shim into the gap, an operator grinds the surface of the solid shim with a tool such as a sander, thereby The shim thickness was manually adjusted.

  Further, conventionally, when a laminate shim is used, prior to inserting the laminate shim into the gap, an operator uses a tool such as a cutter disclosed in Patent Document 2 to remove the laminate shim from the laminate shim. The thickness of the laminate shim has been manually adjusted by completely or partially peeling at least one layer including the outermost layer.

JP 2004-148700 A JP 2001-353381 A

  Thus, conventionally, regardless of the type of shim used, it is necessary to adjust the thickness of the shim by manual processing by the operator. There is a limit to improvement, and therefore there is a limit to reducing the work cost.

In view of such circumstances, the present invention has been made with the object of providing a technique for efficiently producing a shim inserted into a gap between the two members assembled to each other. It is.

In order to solve the problem, according to one aspect of the present invention, a workpiece is moved between two members that are assembled together by machining the workpiece by moving the tool relative to the plate-like workpiece. A shim manufacturing method for manufacturing a shim inserted into a gap in order to fill a planar gap.
  The workpiece has a surface on which surface processing is performed and a back surface on which the surface processing is not performed.
  Attach the workpiece to the surface of the pallet with the support layer on the back of the workpiece,
  With the pallet mounted on the processing machine with the workpiece mounted,
  In the processing machine, the surface processing and trimming processing are performed on the workpiece,
  During the trimming process, the tip of the tool passes through the workpiece in the thickness direction and reaches the inside of the support layer, but does not reach the surface of the pallet. A shim manufacturing method is provided for controlling the position in the thickness direction, thereby manufacturing the shim as part of the workpiece.

  Further, according to another aspect of the present invention, a planar gap that exists between two members assembled to each other by processing the workpiece by moving the tool relative to the plate-shaped workpiece in the processing machine. A shim manufacturing method for manufacturing a shim inserted into the gap to fill
  Based on the two-dimensional distribution of the thickness of the gap, a tool path for performing surface machining and trimming of the workpiece is determined,
  The workpiece has a surface on which the surface processing is performed and a back surface on which the surface processing is not performed.
  Attach the workpiece to the surface of the pallet with the support layer on the back of the workpiece,
  Attach the pallet to the processing machine,
  In the processing machine, the surface processing and the trimming processing are performed on the workpiece,
  During the trimming process, the tip of the tool passes through the workpiece in the thickness direction and reaches the inside of the support layer, but does not reach the surface of the pallet. A shim manufacturing method is provided for controlling the position in the thickness direction, thereby manufacturing the shim as part of the workpiece.

In any one of the shim manufacturing methods, in one specific example, the tool forms a bottomless groove completely penetrating in the thickness direction in the workpiece, whereby the tool passes the workpiece, While dividing into the part which comprises the said shim, and the excess part, it is possible to form the bottomed groove | channel which penetrates only in the thickness direction in the said support layer .

  The following aspects are obtained by the present invention. Each aspect is divided into sections, each section is given a number, and is described in a form that cites other section numbers as necessary. This is to facilitate understanding of some of the technical features that the present invention can employ and combinations thereof, and the technical features that can be employed by the present invention and combinations thereof are limited to the following embodiments. Should not be interpreted. That is, it should be construed that it is not impeded to appropriately extract and employ the technical features described in the present specification as technical features of the present invention although they are not described in the following embodiments.

  Further, describing each section in the form of quoting the numbers of the other sections does not necessarily prevent the technical features described in each section from being separated from the technical features described in the other sections. It should not be construed as meaning, but it should be construed that the technical features described in each section can be appropriately made independent depending on the nature.

(1) In a processing machine, by moving a tool relative to a plate-like workpiece, the workpiece is machined, so that a planar gap existing between two members assembled together is filled in the gap. A shim production method for producing a shim to be inserted,
Input a gap thickness distribution representing a two-dimensional distribution of the gap thickness,
Applying an approximate function having a plurality of parameters to a plurality of thickness points reflecting the input gap thickness distribution, thereby identifying the parameters in relation to the plurality of thickness points, and Defines a three-dimensional free-form surface that approximately interpolates the plurality of thickness points,
Based on the defined three-dimensional free-form surface, a tool path for performing surface machining and trimming of the workpiece is defined,
The workpiece is mounted on a pallet via a double-sided adhesive tape,
Attach the pallet to the processing machine,
In the processing machine, the surface processing and the trimming processing are performed on the workpiece,
During the trimming process, the tip of the tool passes through the workpiece in the thickness direction and reaches the inside of the double-sided adhesive tape, but does not reach the surface of the pallet. Shim manufacturing method to control the position in the thickness direction.

(2) Furthermore,
When at least one of a plurality of machining points constituting the defined tool path is located outside the workpiece as a workpiece outside machining point, the workpiece outside machining point and the plurality of machining points, By applying the bisection method to the machining point in the workpiece located inside the workpiece, at least one non-existing virtual machining point located inside the workpiece is calculated as a dummy thickness point, Correct the gap thickness distribution to reflect the dummy thickness point,
The shim manufacturing method according to item (1), wherein the three-dimensional free-form surface is redefined based on the corrected gap thickness distribution.

(3) By processing the workpiece by moving the tool relative to the plate-shaped workpiece in the processing machine, the planar clearance existing between the two members assembled together is filled in the clearance. A shim production method for producing a shim to be inserted,
The workpiece has a flat surface portion having a thickness, and a side edge portion surrounding the flat surface portion from the side,
The shim has a flat surface portion having a thickness, and a side edge portion surrounding the flat surface portion from the side,
The machining is a three-dimensional surface machining performed on the flat surface portion of the shim using a first tool and a trimming performed on a side edge portion of the shim using a second tool. Processing and
The shim production method is
A gap thickness distribution in which a plurality of measurement values acquired by individually measuring a plurality of measurement points allocated on the same plane and spatially discretely are associated with each measurement point. A gap thickness distribution input step for inputting a two-dimensional distribution of the gap thickness;
Based on the input gap thickness distribution and the two-dimensional position coordinates of each of the plurality of measurement points, a plurality of thickness points corresponding to the plurality of measurement points, corresponding to each measurement point. Applying a predetermined approximation function having a plurality of parameters to those defined by the two-dimensional position coordinates to be measured and the corresponding thickness measurement values. A surface defining step for identifying a three-dimensional free-form surface that is identified in relation to a thickness point and thereby approximately interpolates the plurality of thickness points;
A machining point calculation step of calculating a plurality of discrete machining points that the first tool should pass to perform the surface machining based on the defined three-dimensional free-form surface;
A first tool path representing a three-dimensional first tool path defined by the machining points, which the first tool should pass to perform the surface machining, based on the plurality of calculated machining points. A first tool path data creating step for creating data and a second tool path representing what the second tool should pass in order to perform the trimming process based on data representing a target shape of the side edge of the shim A second tool path data creation step for creating data;
The first adhesive surface of the double-sided adhesive tape is bonded to the surface of the pallet in a state that is not separable during processing and is separable by external force after the processing is completed. A non-processed surface, which is the surface opposite to the processing surface on which the surface processing is performed, of both surfaces of the workpiece is not separable during processing on the second bonding surface on the side opposite to the one bonding surface, and processing ends After that, in a state where it is separable by an external force, a pallet preparation process for preparing the pallet,
A pallet mounting step for detachably mounting the prepared pallet on the processing machine;
Based on the created first tool path data, the working surface of the work mounted on the processing machine is three-dimensionally moved by moving the first tool relative to the processing machine three-dimensionally. A surface processing step of creating a planar portion of the shim,
When the surface machining is finished, the side edge of the set workpiece is moved by moving the second tool relative to the machine based on the created second tool path data. Trimming, thereby dividing the workpiece into a part constituting the shim and an extra part, and trimming a side edge of the shim,
In the trimming process, during the trimming process, the second tool penetrates the entire thickness of the workpiece from the processed surface toward the non-processed surface, whereby the second tool is Having a protrusion protruding from the processing surface toward the surface of the pallet;
In the trimming process, the tip of the protrusion reaches the inside of the double-sided adhesive tape at the closest position where the second tool is closest to the surface of the pallet during the trimming process. A shim manufacturing method for controlling the position of the second tool in the thickness direction of the workpiece so as not to reach the surface of the pallet.

(4) Furthermore,
In the three-dimensional space defining the shim, when at least one of the plurality of calculated machining points is located outside the workpiece, the shim has at least one auxiliary located inside the workpiece. A gap thickness distribution correcting step of adding an additional thickness point and correcting the gap thickness distribution to reflect the added auxiliary thickness point;
When the gap thickness distribution correction step is executed, based on the corrected gap thickness distribution and the two-dimensional position coordinates of each of the plurality of measurement points including the added auxiliary thickness point, Correcting the plurality of thickness points and applying the approximation function to the corrected plurality of thickness points, thereby identifying the plurality of parameters in relation to the corrected plurality of thickness points; And a surface redefinition step of defining a three-dimensional free-form surface that approximately interpolates the corrected plurality of thickness points as a corrected three-dimensional free-form surface.

(5) The shim manufacturing method is implemented to manufacture a plurality of shims used for assembling the same structure.
The shims are sorted into groups in the same order that the corresponding gap thickness distributions are each entered,
The shim production method is
Furthermore, a plurality of shims belonging to each group are nested to enable production from the same workpiece collectively, thereby producing a plurality of shims belonging to each group on the same workpiece prior to the processing. Including a nesting step of allocating a plurality of processing regions to be arranged in a plane,
In the first and second tool path data creation steps, the processing machine performs the surface processing and the trimming processing for each workpiece by regarding a plurality of shims belonging to each workpiece as one product. The shim manufacturing method according to (3) or (4), wherein the first and second tool path data are created.

(6) In the first and second tool path data creation steps, when the surface processing and trimming processing for all of the plurality of processing regions are completed, the entire next processing region adjacent thereto Generating the first and second tool path data such that the first and second tool paths are defined such that the surface machining and the trimming process are initiated for the first and second tool paths. When two tools pass once from the first to the last of the plurality of machining areas, at that time, the surface machining and the trimming for the plurality of machining areas are continuously performed (5 The shim manufacturing method according to the item).

(7) In the first and second tool path data creation steps, when the surface processing and trimming processing for any part of the plurality of processing regions are completed, the next processing region adjacent thereto The first and second tool path data are generated such that the first and second tool paths are defined such that the surface processing and the trimming process are started for a part, whereby the first and second tool path data are generated. When the second tool passes a plurality of times from the first to the last of the plurality of processing regions, the surface processing and the trimming processing for the plurality of processing regions are completed. The shim manufacturing method according to item (5), wherein time division processing is performed.

(8) The shim manufacturing method according to any one of (1) to (7), wherein each of the shims is a solid shim including a single layer made of metal, synthetic resin, or composite material.

(9) The shim according to any one of (1) to (7), wherein each of the shims is a laminate shim in which a plurality of layers made of metal, synthetic resin, or composite material are detachably laminated. Production method.

(10) A program executed by a computer to implement the method according to any one of (1) to (9).

(11) A recording medium on which the program according to item (10) is recorded so as to be readable by a computer.

FIG. 1 is a block diagram conceptually showing an example of an environment in which a shim manufacturing method according to an embodiment of the present invention is executed. FIG. 2A is a perspective view showing an example of a shim manufactured by the shim manufacturing method, and FIG. 2B is a partial view of an example of a workpiece that is processed to manufacture the shim. It is a perspective view shown. FIG. 3 is a flowchart conceptually showing the shim manufacturing method. FIG. 4 is a flowchart conceptually showing one specific example of step S1 in FIG. FIG. 5 is a flowchart conceptually showing a specific example of a series of steps including steps S2 to S5 shown in FIG. FIG. 6 is a side view showing an example of a correspondence relationship between a measurement point sequence and a processing point sequence, that is, a thickness point sequence, for explaining a specific example of a series of steps including steps S2 to S5 shown in FIG. . FIG. 7A is a conceptual diagram for explaining how the gap thickness distribution is reported from the assembly site to the manufacturing site in order to explain a specific example of step S8 shown in FIG. (B) is a conceptual diagram for explaining an example of the structure of data representing the gap thickness distribution and the definition of thickness points. Fig.8 (a) is a top view which shows partially an example of the path | route which a tool is moved when carrying out surface processing of the workpiece | work shown in FIG.2 (b) by a continuous processing method, FIG.8 (b), It is a top view which shows partially an example of the path | route to which a tool is moved when carrying out surface processing of the said workpiece | work by the time division processing method. FIG. 9 is a perspective view showing a pallet on which the workpiece shown in FIG. 2B is mounted and which is mounted on the processing machine shown in FIG. FIG. 10A is a cross-sectional view showing the pallet shown in FIG. 9 in a state where a work is mounted via a double-sided adhesive tape, and FIG. 10B shows only the double-sided adhesive tape in an enlarged manner. It is sectional drawing. FIG. 11A is a cross-sectional view showing a state in which the workpiece shown in FIG. 10A is surface-treated by executing one specific example of step S11 in FIG. 3, and FIG. FIG. 11 is a cross-sectional view showing a state in which the work shown in FIG. 10A is trimmed by executing one specific example of step S12 in FIG. FIG. 12 is a flowchart conceptually showing a specific example of a series of steps related to processing by the processing machine shown in FIG. FIG. 13 is a flowchart conceptually showing a specific example of step S90 shown in FIG.

  Hereinafter, some exemplary and specific embodiments of the present invention will be described in detail with reference to the drawings.

  As shown in FIG. 1, a shim manufacturing method (hereinafter simply referred to as “the present method”) according to an embodiment of the present invention is performed at a manufacturing site MS in which a data creation device 10 and a processing machine 12 are installed.

  The data creation device 10 creates processing data necessary for the processing machine 12 to manufacture shims based on the gap thickness distribution acquired from the assembly site AS. At the assembly site AS, an operator assembles a structure such as an aircraft by assembling a plurality of parts with each other. In the assembly site AS, when an unscheduled gap exists between two parts (members) to be assembled with each other, the gap is filled by inserting a shim 20 into the gap, thereby Random relative displacement between two parts separated by a gap is prevented. A plurality of shims 20 are used for one structure.

  Therefore, at the manufacturing site MS, the shim 20 is automatically manufactured according to the thickness of the gap to be filled. That is, the thickness of the shim 20 is automatically adjusted according to the thickness of the gap to be filled. In the production site MS, in order to manufacture the shim 20, a path for moving the tools 30, 32 relative to the workpiece 40 in the processing machine 12 is determined, and the tools 30, 32 are moved along the path. Thus, surface processing and trimming processing are performed on the workpiece 40.

  Prior to the fabrication of the shim 20, at the assembly site AS, the operator measures the thickness of the gap to be filled by the shim 20, and represents the gap thickness distribution (the two-dimensional thickness of the shim 20). (Distribution) is reported to the production site MS. The shim 20 produced by the processing machine 12 at the production site MS is delivered to the assembly site AS, and the worker inserts the delivered shim 20 into the corresponding gap at the assembly site AS.

  FIG. 7B shows an example of a data structure representing the gap thickness distribution. In this example, the combination of the number i of the shim 20 and the number j of the measurement point belonging to the shim 20, the two-dimensional position coordinates (x, y) of the measurement point, and the thickness z corresponding to the measurement point Are associated. A thickness point (x, y, z) defined by three-dimensional coordinates is assigned to each measurement point. By a set of a plurality of thickness points assigned to a plurality of measurement points belonging to the same shim 20, a processing surface 90 (a target surface to be processed among the target three-dimensional shape of the surface of the shim 20, that is, both surfaces of the workpiece 40). The target three-dimensional shape shown in FIG. 10 is approximated.

  Referring to FIG. 1 again, the data creation device 10 is mainly composed of a computer having a processor and a memory, although not shown. The memory stores a program (for example, a machining data creation program described later) and data necessary for carrying out this method. The data includes, for example, the gap thickness distribution, an approximate function for approximating the target three-dimensional shape of the surface of the shim 20 with a curved surface, a plurality of parameters for defining the characteristics of the approximate function, and for surface processing First tool path data, second tool path data for trimming, and the like. Data representing the gap thickness distribution supplied from the assembly site AS to the production site MS is stored in the memory of the data creation device 10. When the creation of necessary machining data is completed, the data creation device 10 supplies the machining data to the processing machine 12.

  The processing machine 12 is based on the supplied processing data and in accordance with a command from the operator, tools 30, 32 (for example, a ball end mill 30 for surface processing (an example of a “first tool”), By operating the flat end mill 32 (an example of “second tool”) for trimming, the tools 30 and 32 are moved relative to the plate-like workpiece 40 along the tool path. The shim 20 is manufactured by machining the workpiece 40.

  The type of the workpiece 40 includes, for example, a single-layer plate material made of a single layer made of metal (for example, aluminum), synthetic resin (for example, polyimide) or a composite material, metal, or synthetic resin. Alternatively, there is a multilayer plate-like material in which a plurality of layers made of a composite material are laminated so as to be peeled from each other. In the present embodiment, for example, a multi-layered plate-like material in which a plurality of layers made of synthetic resin are laminated so as to be peelable from each other is adopted as the workpiece 40. It is not limited.

  The types of the tool path include, for example, a reciprocating path by a cross-sectional method (for example, a plurality of straight paths arranged at approximately equal intervals at pick feed intervals), a contour path along a contour line, and a curved path by a surface along method. and so on. In the present embodiment, the tool path is determined as a reciprocating path by the cross-sectional method, but the types of tool paths to which the present invention can be applied are not limited to this.

  The type of shim 20 includes, for example, a solid shim made of metal, synthetic resin or composite material, and a laminate shim in which each layer is made of metal, synthetic resin or composite material (in the industry, “multi-layer shim”). Also called). In this embodiment, a laminate shim in which each layer is made of a synthetic resin is adopted as the shim 20, but the type of the shim 20 to which the present invention can be applied is not limited to this.

  Although not shown, the processing machine 12 is, as is well known, for example, a head that holds the tools 30 and 32, a first drive unit that moves the head, and a second drive unit that rotates the tools 30 and 32. A table on which the workpiece 40 is set, a control unit that controls the first and second drive units, a cover that covers the entire processing machine 12, and a cover that is provided on the cover. And an opening that allows access to a head and a table that are present in the processing area, and a door that is provided in the cover and that is operated by an operator to open and close the opening. Is done. In the control unit, the processor controls the entire processing machine 12 by executing a processing control program (described later) stored in the memory, thereby manufacturing the shim 20.

  As shown in FIG. 2A, the shim 20 includes a flat surface portion 50 having a thickness and a side edge portion 52 that surrounds the flat surface portion 50 from the side. The shim 20 has a flat plate shape (when no forced external force is applied) before being inserted into the corresponding gap, but when inserted into the gap, the contact of the shim 20 is due to its own flexibility. It deforms so as to follow the shape of the surface of the part being operated. That is, the shim 20 can be referred to as a three-dimensional shim. As a result, each side of the shim 20 is at least partially in contact with the opposing surfaces of the two parts spaced apart. As a result, the corresponding gap is filled and unscheduled relative displacement between the two parts across the gap is prevented.

  On the other hand, as shown in FIG. 2B, the workpiece 40 has a flat surface portion 60 having a thickness and a side edge portion 62 surrounding the flat surface portion 60 from the side. In the present embodiment, as will be described in detail later, a plurality of processing areas WA in which a plurality of shims 20 are to be manufactured are assigned to the same workpiece 40 so as to be arranged in a plane. That is, when allocating to one work 40, nesting is performed on a plurality of shims 20.

  Next, the method will be schematically described with reference to FIG. 3. The method includes a gap thickness distribution input step S <b> 1, a curved surface definition step S <b> 2, in order for the data creation device 10 to create machining data. , Machining point calculation step S3, gap thickness distribution correction step S4 (S4a and S4b), curve redefinition step S5, first tool path data creation step S6, second tool path data creation step S7, nesting Step S8. These steps S1 to S8 are executed when the processor of the data creation device 10 executes the machining data creation program.

  First, the gap thickness distribution input step S1 will be described. In this step S1, the data creation device 10 uses a plurality of measurement points in which the gap thickness is allocated on the same plane and spatially discretely. A gap thickness distribution representing a plurality of measurement values acquired by being individually measured in association with each measurement point, which represents a two-dimensional distribution of the gap thickness, is input.

  Here, a specific example of the flow of the gap thickness distribution input step S1 will be described with reference to the flowchart of FIG.

  In this example, first, in step S51, among the plurality of shims 20 belonging to the same structure, the shim i of the shim 20 of interest this time is set to 1. Next, in step S52, the number of measurement points N (i), which is the number of measurement points belonging to the current shim 20, is read from the memory. Subsequently, in step S53, among the plurality of measurement points belonging to the current shim 20, the measurement point number j of the measurement point of interest is set to 1.

  Thereafter, in step S54, the two-dimensional position coordinates x (j) and y (j) corresponding to the current measurement point are read from the memory. Subsequently, in step S55, the thickness z (j) corresponding to the current measurement point is read from the memory. Thereafter, in step S56, the three-dimensional position coordinates x (j), y (j), z (j) defining the current thickness point are associated with the combination of the current shim 20 and the current measurement point, Stored in the memory.

  Subsequently, in step S57, it is determined whether or not the current value of the measurement point number j has reached the number of measurement points N (i). Assuming that it has not yet reached this time, after the measurement point number j is incremented by 1 in step S58, the process returns to step S54, and steps S54 to S57 are similarly performed for the next measurement point. The

  Assuming that the current value of the measurement point number j has reached the number of measurement points N (i) as a result of the execution of steps S54 to S58 several times, in step S59, the current value of the shim number i is the total number of shims S. It is determined whether or not it has been reached. Assuming that it has not yet reached this time, after the shim number i is incremented by 1 in step S60, the process returns to step S52, and steps S52 to S60 are similarly executed for the next shim 20. .

  Assuming that the current value of the shim number i has reached the total number of shims S as a result of the execution of steps S52 to S60 being repeated several times, the current execution of the gap thickness distribution input step S1 is completed.

  Referring again to FIG. 3, in the curved surface definition step S <b> 2, the data creation device 10 uses the plurality of thickness points corresponding to the shims 20 (that is, the input gap thickness distribution and the plurality of the plurality of thickness points). A plurality of thickness points corresponding to the plurality of measurement points based on the two-dimensional position coordinates of the measurement points, and for each measurement point, the corresponding two-dimensional position coordinates and the corresponding thickness A predetermined approximation function (for example, a B-spline function, a Bezier function, etc.) having a plurality of parameters, thereby applying the parameters to the plurality of parameters. A three-dimensional free-form surface that is identified in relation to the thickness points and thereby approximately interpolates the plurality of thickness points is defined.

  Thus, in the present embodiment, the thickness of the gap into which the shim 20 is to be inserted is measured spatially discretely only at some representative points (the plurality of measurement points) by the operator, and then the data The creation device 10 interpolates the plurality of thickness measurement values (the plurality of thickness points) with a free-form surface, so that the two-dimensional distribution of the thickness in the gap of interest is automatically automatically spatially continuous. Is estimated.

  Next, in the machining point calculation step S3, the data creation device 10 performs surface machining by the cross-sectional method based on the defined curved surface, the advancing direction feed speed and the pick feed speed of the first tool 30. Therefore, a plurality of discrete machining points that the first tool 30 should pass through are calculated.

  Next, in the gap thickness distribution correction step S <b> 4, the data creation device 10 is outside the workpiece 40 at any one of the calculated machining points in the three-dimensional space defining the shim 20 (workpiece If it is located outside the space occupied by 40 (in FIG. 3, if the determination in step S4a is YES), the shim 20 has at least one auxiliary thickness point (corresponding to it) located inside the workpiece 40. Defined by the x-coordinate value, y-coordinate value, and z-coordinate value), and the gap thickness distribution (the plurality of thickness points) to reflect the added auxiliary thickness point. Correction is performed (step S4b).

In the curved surface redefinition step S5, the data creation device 10 includes the plurality of measurements including the corrected gap thickness distribution (relationship between the plurality of measurement points and the thickness) and the added auxiliary thickness points. Based on the two-dimensional position coordinates of each point, the plurality of thickness points are corrected (the first plurality of thickness points (x _j , y _j , z _j )). _k , y _k , z _k ) are added).

  Further, the data generating device 10 applies the approximation function to the corrected plurality of thickness points, thereby identifying the plurality of parameters in relation to the corrected plurality of thickness points, Thus, a three-dimensional free-form surface that approximately interpolates the plurality of corrected thickness points is defined as a corrected three-dimensional free-form surface.

  Here, a specific example of a series of steps including steps S2 to S5 shown in FIG. 3 will be described with reference to the flowchart of FIG.

  In this example, first, in step S81, data representing the plurality of thickness points is input from the memory for the current shim 20. Next, in step S82, the approximate function is applied to the plurality of thickness points to identify a plurality of parameters for the approximate function. For example, the plurality of parameters are identified so that the deviation between the free-form surface described by the approximation function and the positions of the plurality of thickness points, that is, the approximation error is minimized.

  Subsequently, in step S83, the number of corrections for correcting the thickness point (which is also the number of corrections for the machining point and the number of corrections for the free-form surface) is reset to zero. Thereafter, in step 84, a free-form surface that interpolates a plurality of thickness points corresponding to the current shim 20 is defined by the identified parameters and the approximate function. This free-form surface is the target three-dimensional shape of the processed surface of the workpiece 40, and is also the target three-dimensional shape of the surface of the shim 20.

  Subsequently, in step S85, using the defined free-form surface and the pick feed interval, three-dimensional positions of a plurality of machining points defining a plurality of tool paths are calculated based on the section method. . In the present embodiment, the tool path is defined to mean a path defined by a machining point sequence (movement locus of machining points), but the definition of the tool path is not limited to this, for example, It can be defined to mean the movement trajectory of the tool center point of the tools 30 and 32. When the tools 30 and 32 are ball end mills, the position of the machining point is calculated by combining the tool center point and the tool radius.

  FIG. 6 shows, as an example, several tool paths, a sequence of machining points P corresponding to each tool path, and a sequence of measurement points M corresponding to the machining points P.

  In this example, for convenience of explanation, the measurement point M and the processing point P are illustrated in a one-to-one correspondence, and the corresponding measurement point M and the processing point P are shown to share the same xy coordinate value. However, in practice, a one-to-one relationship is not established between the measurement point M and the processing point P. However, a one-to-one relationship is established between the measurement point M and the thickness point.

  The curve that connects the point sequence of the processing points P basically matches the curve that connects the sequence of thickness points. This is because the point sequence of the machining points P is located on the tool path obtained by curve interpolation of the point sequence of the thickness points. Then, if the point sequence of the thickness points is located inside the workpiece 40, the point sequence of the processing points P seems to be located inside the workpiece 40.

  However, the processing point P does not necessarily coincide with the thickness point with respect to the coordinate position. Further, in the tool path, a portion passing through each thickness point can be secured by managing the position coordinates of the thickness point so that it is positioned inside the workpiece 40, whereas the tool path can be secured. A portion of the path that does not pass through each thickness point may be located outside the workpiece 40 even if the above management is performed. Therefore, there is a possibility that the processing point P is located outside the workpiece 40.

  Therefore, as shown in FIG. 3, in step S <b> 86, it is determined whether a machining point existing outside the workpiece 40 exists among the plurality of machining points calculated for the current shim 20. For example, in the example shown in FIG. 6 (a), none of the processing points P1, P2, P3 exists outside the workpiece 40, but in the example shown in FIG. 6 (b), the processing points P1 and P3 are Although present inside the workpiece 40, the processing point P <b> 2 exists outside the workpiece 40.

  If any machining point exists inside the workpiece 40, in step S87, it is permitted to create tool path data (for surface machining and trimming) using a plurality of machining points this time. This is the end of the current execution of this flow.

  On the other hand, if any machining point exists outside the workpiece 40, it is determined in step S88 whether the number of corrections exceeds the upper limit A. If the number of corrections exceeds the upper limit A, it is desirable that the current shim 20 is not automatically manufactured by the processing machine 12 but manually processed in step S89. Is instructed. This is the end of the current execution of this flow.

  If the number of corrections does not exceed the upper limit A, an auxiliary thickness point (that is, a dummy thickness point) is acquired in step S90. The acquisition may be performed by the data creation device 10 at least partially requiring operator intervention, but it is more desirable that the acquisition be performed completely automatically without operator intervention. In the example shown in FIG. 6C, the auxiliary thickness point T2-3 is automatically acquired with respect to the example shown in FIG.

According to an example of an algorithm for automatically calculating an auxiliary thickness point (that is, a dummy thickness point) in step S90 shown in FIG. 5, schematically, out of the plurality of calculated processing points. When at least one of the machining points is located outside the workpiece 40 as a machining point outside the workpiece, the bisection method is performed on the machining point outside the workpiece and the machining point located inside the workpiece 40 among the plurality of machining points. By applying the above, at least one non-existing virtual machining point located inside the workpiece 40 is calculated as a dummy thickness point. The gap thickness distribution is corrected to reflect the dummy thickness point.

  FIG. 13 is a flowchart showing a specific example of step S90.

  In this example, first, in step S201, a workpiece outside machining point located outside the workpiece 40 among the plurality of machining points is set as a first limit point. The first limit point corresponds to one of two limit points (section upper limit and section lower limit) that define a section to which the bisection method is applied, and the other is a second limit point described later.

  Next, in step S202, among the plurality of machining points, the one located in the workpiece 40 and close to the current workpiece outside machining point (for example, the closest one) is the proximity machining point. Selected as. Subsequently, in step S203, the selected proximity processing point is set as the second limit point.

  Thereafter, in step S204, the current section of interest, that is, the section defined by the workpiece outside machining point and the adjacent machining point is divided into two equal parts, and the midpoint of the section is calculated. Subsequently, in step S205, it is determined whether or not the calculated intermediate point is located inside the workpiece 40. This time, assuming that the midpoint is located outside the workpiece 40, the midpoint of this time is set as the first limit point in step S206. As a result, the first limit point moves from the workpiece outside machining point to the current intermediate point, and as a result, approaches the proximity machining point.

  Thereafter, in step S207, a new intermediate point is calculated for the new section. Specifically, the current interval, that is, the interval defined by the immediately preceding intermediate point and the adjacent machining point is divided into two equal parts, and the intermediate point of the interval is calculated. Subsequently, the process returns to step S205. The execution of steps S205 to S207 is repeated until an intermediate point existing in the workpiece 40 is searched. When an intermediate point existing in the workpiece 40 is searched, the intermediate point is set as a dummy thickness point to be obtained in step S208. This is the end of the current execution of this flow.

  More specifically, in the example shown in FIG. 6B, first, a machining point P2 located outside the workpiece 40, and another machining point adjacent to the machining point P2 and located inside the workpiece 40. The processing point P3 is extracted as two target processing points. Next, a three-dimensional coordinate of an intermediate point between the target processing points, for example, a geometric midpoint is calculated. For example, the three-dimensional coordinates of the midpoint (candidate of the auxiliary thickness point T2-3) are the average value of the x-coordinate values and the average value of the y-coordinate values for the two target processing points P2 and P3. and an average value of z coordinate values.

  Subsequently, it is determined whether or not the current intermediate point is located inside the workpiece 40. If the current intermediate point is located inside the workpiece 40, the current intermediate point is the final auxiliary thickness point T2-3. Are added to the plurality of thickness points. On the other hand, when the current intermediate point is located outside the workpiece 40, the intermediate point and the machining point P3 located inside the workpiece 40 are adopted as two new attention machining points. For the target processing point, a new intermediate point is calculated in the same manner as described above.

  In this example, a section defined by the first two machining points P2 and P3 (target machining points) is sequentially divided by the bisection method, and the division is an intermediate point (inside the workpiece 40) ( Iterate until an auxiliary thickness point) is searched.

  When the auxiliary thickness point is acquired as described above, in step S91, the number of corrections is incremented by 1. Subsequently, in step S92, the auxiliary thickness point acquired this time is the plurality of thickness points. Thus, the set of thickness points (ie, the gap thickness distribution) is corrected.

  Subsequently, in step S93, as in step S82 described above, the approximate function is applied to the corrected plurality of thickness points, so that a plurality of parameters for the approximate function are identified again. . Thereafter, in step S94, as in step S84, a free-form surface that interpolates a plurality of thickness points corresponding to the current shim 20 is defined again by the identified parameters and the approximate function. Subsequently, the process returns to step S85.

  As a result of adding an appropriate number of appropriate auxiliary thickness points to the latest set of thickness points, when all the processing points are present inside the workpiece 40, in step S87, a plurality of current processing points are obtained. It is allowed to create tool path data using This is the end of the current execution of this flow.

  Referring again to FIG. 3, subsequently, in the first tool path data creation step S <b> 6, the data creation device 10 includes a plurality of calculated machining points (all machining points exist inside the workpiece 40). The first tool path data representing the three-dimensional first tool path defined by these machining points and which the first tool 30 should pass in order to perform the surface machining is created. A first tool path is defined by the calculated sequence of machining points.

  Next, in the second tool path data creation step S <b> 7, the data creation device 10 performs the trimming process based on the data (contour data) representing the target shape of the side edge 52 of the shim 20. 2nd tool path data showing what should pass is created. The contour data is stored in advance in the memory for each shim 20.

  By the way, in this embodiment, the plurality of shims 20 used for assembling the same structure are manufactured so that the size and number of workpieces 40 to be used, and thus the number of times of machining by the processing machine 12 are minimized. The method is carried out for this purpose. In the present embodiment, as illustrated in FIG. 7A, all the shims 20 are classified into a plurality of groups, and a plurality of shims 20 belonging to each group can be manufactured together from the same workpiece 40. Nesting (multiple picking) is performed to make it.

  Therefore, in this embodiment, as shown in FIG. 3, a nesting step S8 is performed. In this nesting step S8, prior to machining of each workpiece 40, as shown in FIG. 2B, a plurality of machining areas WA in which a plurality of shims 20 belonging to each group are to be produced on the same workpiece 40, respectively. It is assigned to line up in a plane.

  In the present embodiment, the target shape (contour shape) of the side edge 52 of each shim 20 is predetermined for each shim 20. Basically, the target contour shape of the shim 20 is different for each shim 20. Therefore, if the information for identifying the shim 20 of interest, for example, the shim number is known, the target shape of the side edge 52 of the shim 20 can be known without performing any measurement. Therefore, with respect to the measurement of the gap thickness distribution, the operator performs only the measurement of the two-dimensional distribution of the thickness of the corresponding gap at the assembly site AS, and the contour shape of the shim 20 to be inserted into the gap is determined. There is no need to measure or specify.

  The fact that the outer shape of each shim 20 is predetermined is convenient for nesting the shims 20. This is because when a plurality of shim processing areas WA are allocated to one workpiece 40, an appropriate portion is reduced as much as possible (that is, the yield of the workpiece 40 is improved). It is important to select a plurality of shims 20 and place the selected shims 20 on the work 40 while being packed together. Therefore, in order to reduce the calculation load of the data creation device 10, a plurality of shims 20 that should belong to a plurality of groups to which the plurality of shims 20 should be classified are determined in advance, and a plurality of shims 20 belonging to one group are further determined. It is important that the layout for arranging the shims 20 on one work 40 is also determined in advance.

  In order to achieve the approach described above, it is necessary to understand and cooperate with the operator at the assembly site AS that reports the gap thickness distribution to the production site MS. In some specific examples, at the assembly site AS, the operator measures the gap thickness distribution for each of the plurality of gaps according to the order rules specified by the production site MS. Further, in the assembly site AS, the operator classifies the plurality of shims 20 into a plurality of groups according to the rules regarding grouping designated by the production site MS, and further, for each group, a plurality of gaps belonging to each group. The thickness distribution of is reported to the production site MS.

  Specifically, in the example shown in FIG. 7A, the worker at the assembly site AS has a plurality of shims 20 belonging to the first group among the plurality of shims 20 used for assembling the same structure. Therefore, the corresponding gap thickness distribution is summarized and reported to the production site MS. Next, the operator at the assembly site AS reports the gap thickness distributions corresponding to the plurality of shims 20 belonging to the second group to the production site MS. Subsequently, the worker at the assembly site AS reports the gap thickness distribution corresponding to the plurality of shims 20 belonging to the third group to the production site MS.

  Thereafter, at the production site MS, as shown in FIG. 7A, the data creation device 10 assigns the plurality of shims 20 belonging to the first group to the first work 40, and assigns the plurality of shims 20 belonging to the second group. The second work 40 is assigned, and a plurality of shims 20 belonging to the third group are assigned to the third work 40.

  In practice, however, there is a possibility that the measured value of the gap thickness distribution does not exist for some of the plurality of shims 20 belonging to a certain group. In this case, the gap thickness distribution Only a plurality of shims 20 excluding the shim 20 having no measurement value may be targeted for nesting.

  Further, when a plurality of shims 20 belonging to the same group are allocated on the machining surface 90 (see FIG. 10) of one workpiece 40, the overall layout (relative position) of the shims 20 is as long as the combination of the shims 20 is the same. The same layout may be adopted, but different layouts may be adopted.

  As shown in FIG. 3, in this nesting step S <b> 8, the processing machine 12 further performs surface processing and trimming processing for each workpiece 40 by regarding the plurality of shims 20 belonging to each workpiece 40 as one product. In order to do so, a plurality of first tool paths created in the first tool path data creation step S6 and a plurality of second tool paths created in the second tool path data creation step S7 are continuously provided. Integrated into one tool path.

  There are several approaches when defining a tool path by regarding a plurality of shims 20 belonging to each workpiece 40 as one product.

  According to the first approach, a plurality of data creation devices 10 are provided in the first and second tool path data creation steps S6 and S7 as shown in FIG. When the surface processing and trimming processing for the entire one of the processing regions WA (first processing region WA1) is completed, the surface processing and trimming processing are started for the entire next processing region WA adjacent thereto. First and second tool path data are generated so that the first and second tool paths are defined. Accordingly, when the first and second tools 30 and 32 pass once from the first to the last of the plurality of processing areas WA, the surface processing and trimming processing for the plurality of processing areas WA are performed at that time. Finished continuous machining is performed.

  In FIG. 8A, for convenience of explanation, only the first tool path represented by the first tool path data for surface processing is indicated by a solid line. In one example, after the surface processing for all the shim processing areas WA is completed, the tool to be used is changed from the ball end mill 30 to the flat end mill 32, and then the trimming processing for all the shim processing areas WA is performed. In the same manner as in the case of the surface processing, when the whole of a certain shim 20 is finished, the process is executed so that the whole of the next shim 20 is started.

  According to the second approach, a plurality of data creation devices 10 are provided in the first and second tool path data creation steps S6 and S7 as shown in FIG. When the surface processing and trimming processing for a part of any one of the processing areas WA (first processing area WA1) is completed, the surface processing and trimming processing for a part of the next processing area WA adjacent thereto is started. First and second tool path data are generated so that the first and second tool paths are defined as described above. As a result, the first and second tools 30 and 32 are arranged in a line (for example, linearly arranged) among the plurality of machining areas WA. When a plurality of processing areas WA are repeated a plurality of times, the surface processing and trimming processing for several processing areas WA arranged in a line (for example, linearly arranged) are completed. Is done.

  In FIG. 8B, for convenience of explanation, only the first tool path represented by the first tool path data is shown by a solid line. In one example, after the surface processing for all the shim processing areas WA is completed, the tool to be used is changed from the ball end mill 30 to the flat end mill 32 and is aligned in a line (for example, linearly aligned). ) When trimming processing for some shim processing areas WA is completed for a part of a certain shim 20 in the same manner as in the case of surface processing, execution is performed so that it is started for a part of the next shim 20 Is done.

  According to this time division processing, the time during which the same tools 30 and 32 continuously act on the same workpiece 40 is shortened. For example, when the workpiece 40 is easily heated by friction with the tools 30 and 32, Nevertheless, the heating of the workpiece 40 is suppressed. In addition, according to this time-sharing process, the number of times the tools 30 and 32 are reciprocated on the workpiece 40 is reduced, and the number of times the movement of the tools 30 and 32 is reversed with respect to the traveling direction thereof is also reduced. The frequency of acceleration / deceleration of the tools 30, 32 in the traveling direction thereof is also reduced. This is advantageous in order to reduce the processing time of the workpiece 40 and reduce the load on the processing machine 12.

  In one example, the surface processing is performed by moving the first tool 30 relative to the workpiece 40 in a reciprocating mode. In this case, in order to create a tool path, first, a plurality of straight path segments arranged at equal intervals and in parallel with each other with a predetermined pick feed are assumed as candidate straight path segments.

  In this example, among the candidate straight path segments, the representative gap thickness corresponding to each candidate straight path segment (for example, an average value of a plurality of gap thicknesses corresponding to a plurality of measurement points belonging to each candidate straight path segment ) Is less than or equal to a predetermined threshold value between adjacent candidate straight path segments, one of the two candidate straight path segments adjacent to each other is excluded from the final tool path. As described above, a part of the plurality of candidate straight path segments is thinned out by paying attention to the variation amount of the representative gap thickness.

  According to this example, the number of straight path segments is reduced without significantly reducing the accuracy of the surface shape of the shim 20, and thus the overall length of the tool path is shortened, and further, the necessary machining time is shortened. .

  Referring to FIG. 3 again, the method further includes a pallet preparation step S9 and a pallet mounting step S10 in order for the operator to prepare for machining.

  In the pallet preparation step S9, the operator prepares the pallet 70 by mounting the workpiece 40 on the pallet 70 shown in a perspective view in FIG. 9 and detachably mounted on the table of the processing machine 12. Done. The pallet 70 includes a main body portion 72 made of a plate-shaped material having a generally rectangular shape, and handles 74 attached to both ends of the main body portion 72, respectively. The operator holds the pallet 70 with both hands in order to carry the pallet 70. Have what to do. The main body 72 is made of a metal such as aluminum, and is not deformed by an external force during transportation of the pallet 70 or during processing by the processing machine 12 while ensuring light weight transportability. Material properties, thickness, shape, etc.

  Specifically, in the pallet preparation step S9, the operator places the workpiece 40 on the upper surface of the pallet 70 in a plane posture and through the double-sided adhesive tape 80, as shown in a sectional view in FIG. And glue. The double-sided adhesive tape 80 is also referred to as a pressure-sensitive adhesive layer when the support layer 82 particularly pays attention to the fact that the support layer 82 can be peeled from both sides, as shown in a sectional view in FIG. It is possible to be sandwiched and configured.

An example of a support layer 82 is made of polyester, having a thickness of 0.025 mm. An example of each adhesive layer 84 is an acrylic pressure-sensitive adhesive, and has a thickness of 0.002 mm. The overall thickness of an example of the double-sided adhesive tape 80 is 0.029 mm. An example of the double-sided adhesive tape 80 is a product “Kikuduru Tape No. 192” available from Kikusui Tape Co., Ltd.

  More specifically, in the pallet preparation step S9, as shown in FIG. 10 (a), an operator is processing the first adhesive surface 86 (lower adhesive surface) of the double-sided adhesive tape 80 during processing. Inseparable, after processing is finished, adheres to the surface of the pallet 70 in a state where it can be separated by an external force, and then the second adhesive surface 88 on the opposite side of the first adhesive surface 86 of the adhered double-sided adhesive tape 80. The non-machined surface 92, which is the surface opposite to the machined surface 90 on which the surface machining is performed, of both surfaces of the workpiece 40 is not separable during machining and can be separated by external force after machining. In this state, the pallet 70 is prepared.

  Referring again to FIG. 3, in the pallet mounting step S <b> 10, the operator mounts the prepared pallet 70 on the table of the processing machine 12 in a detachable manner.

  Referring to FIG. 3 again, the method further includes a surface processing step S11 and a trimming step S12 for the processing machine 12 to perform processing.

  In the surface processing step S11, the processing machine 12 moves the first tool 30 relative to the processing machine 12 in a three-dimensional manner based on the created first tool path data. The processing surface 90 of the workpiece 40 mounted on the workpiece 12 is three-dimensionally processed, whereby the surface of the flat portion 50 of the shim 20 is processed (the thickness is adjusted). In one example, as shown in FIG. 11A, the ball end mill 30 is generally perpendicular to the work surface 90 of the workpiece 40, and the tip of the ball end mill 30 does not enter the thickness portion of the double-sided adhesive tape 80 at all. As described above, the workpiece 40 is moved along the machining surface 90 of the workpiece 40, whereby the machining surface 90 of the workpiece 40 is three-dimensionally machined.

  In the trimming processing step S12, the processing machine 12 moves the second tool 32 relative to the processing machine 12 based on the generated second tool path data, whereby the set workpiece 40 is moved. The side edge portion 62 is trimmed, whereby the side edge portion 52 of the shim 20 is trimmed while being divided into a portion constituting the shim 20 and an extra portion.

  In one example, as shown in FIG. 11 (b), the flat end mill 32 is generally perpendicular to the work surface 90 of the workpiece 40, and its tip is partially in the thickness portion of the double-sided adhesive tape 80. So that the non-machined surface 92 of the workpiece 40 is moved along the machining surface 90 of the workpiece 40 such that the non-machined surface 92 of the workpiece 40 is divided into a part constituting the shim 20 and an extra part, thereby The 20 side edge portions 62 are trimmed.

  In the trimming process S12, during the trimming process, the second tool 32 penetrates the entire thickness of the workpiece 40 from the processed surface 90 toward the non-processed surface 92, whereby the second tool 32 is not processed. A protrusion 94 protruding from the surface 92 toward the surface of the pallet 70 is provided. In this trimming process, as shown in FIG. 11B, the tip 96 of the protrusion 94 is attached to the double-sided adhesive tape at the closest position where the second tool 32 is closest to the surface of the pallet 70 during the trimming process. The position of the second tool 32 in the thickness direction of the workpiece 40 is controlled so as to reach the inside of 80 but not to contact the surface of the pallet 70.

  As a result, the second tool 32 has a groove that completely penetrates the workpiece 40 in the thickness direction (a bottomless groove that opens on both the first adhesive surface 86 and the second adhesive surface 88 of the double-sided adhesive tape 80). As a result, the second tool 32 divides the workpiece 40 into a part constituting the shim 20 and an extra part, but the double-sided adhesive tape 80 is only partially penetrated in the thickness direction. Groove (bottomed groove that opens only on the second adhesive surface 88 of the double-sided adhesive tape 80) is formed, so that the second tool 32 comes into contact with the surface of the pallet 70 as well as the double-sided adhesive. Cutting the tape 80 is also prevented.

  In other words, as shown in FIG. 11B, the tip 96 of the protrusion 94 is positioned at the closest position where the second tool 32 is closest to the surface of the pallet 70 during the trimming process. The relationship between the closest position and the thickness of the double-sided adhesive tape 80 is set so as to reach the inside but not contact the surface of the pallet 70.

  Steps S11 and S12 described above are executed when the processor of the processing machine 12 executes the processing control program.

  Here, a specific example of a series of steps related to processing by the processing machine 12 will be described with reference to the flowchart of FIG.

  First, in step S101, the operator adheres the first adhesive surface 86 of the double-sided adhesive tape 80 to the upper surface of the pallet 70 placed in a horizontal posture on the horizontal upper surface of the work table. Next, in step S <b> 102, the operator attaches the lower surface (non-processed surface 92) of the workpiece 40 to the second adhesive surface 88 of the double-sided adhesive tape 80 adhered to the pallet 70. Subsequently, in step S <b> 103, the operator detachably mounts the pallet 70 on which the workpiece 40 is mounted on the upper surface of a table disposed in a horizontal posture in the processing space of the processing machine 12. Thereby, the workpiece 40 is positioned at a predetermined position in the processing machine 12.

  Thereafter, in step S104, the operator closes and locks the door of the processing machine 12, and subsequently, in step S105, in response to the operator operating the processing start switch of the processing machine 12, the processing machine 12 However, three-dimensional surface processing is performed on the processing surface 90 (upper surface) of the workpiece 40. Thereafter, in step S <b> 106, the processing machine 12 performs trimming processing on the workpiece 40. When the trimming process for all the shims 20 is completed, the workpiece 40 is divided into a portion constituting the plurality of shims 20 and an extra portion, and a groove in which no workpiece material exists is formed between these portions. Is done.

  Subsequently, in step S107, the operator unlocks and opens the door of the processing machine 12, and then, in step S108, the operator removes the pallet 70 together with the workpiece 40 from the table of the processing machine 12. Subsequently, in step S <b> 109, the worker places the pallet 70 on the work table and carefully removes the plurality of shims 20 from the pallet 70. Thereafter, in step S <b> 110, the worker deburrs each shim 20. This completes a series of processing operations.

  As apparent from the above description, according to the present embodiment, if the thickness of the gap into which the shim 20 is to be inserted is measured spatially discretely only for some representative points, the data creation device 10 By interpolating these thickness measurements with a free-form surface, it becomes possible to automatically estimate the two-dimensional distribution of the thickness in the gap of interest substantially continuously in space, and thus the shim 20 The target three-dimensional surface shape can be automatically calculated substantially continuously in space.

  Furthermore, according to the present embodiment, the data creation device 10 uses the target three-dimensional surface shape of the shim 20 calculated as described above to perform surface processing and trimming processing of the shim 20 using the processing machine 12. It is possible to automatically calculate a tool path for automatic operation.

  Further, according to the present embodiment, the processing machine 12 can automatically adjust the thickness of the shim 20 by using the calculated tool path. As a result, the working efficiency is improved as compared with the case where the shim 20 has to be processed by hand.

  Furthermore, according to the present embodiment, the accuracy of the estimation accuracy of the two-dimensional distribution of the thickness in the gap of interest is calculated based on the target three-dimensional surface shape of the shim 20 calculated automatically. It is automatically determined by referring to the geometric position.

  Furthermore, according to the present embodiment, when the estimation accuracy of the two-dimensional distribution of the thickness in the gap of interest is poor, another virtual measurement point (because it is a non-existent measurement point, “dummy Is added to the plurality of measurement points (existing measurement points), and another virtual measurement point is added to the virtual point without additional measurement by the operator. Thickness is set. Based on the virtual information, a virtual thickness point (dummy thickness point) is defined as the auxiliary thickness point.

  Furthermore, according to the present embodiment, by using the virtual thickness point, the estimation accuracy of the two-dimensional distribution of the thickness in the gap of interest is improved, and as a result, the calculation accuracy of the target three-dimensional surface shape of the shim 20 is improved. Will improve. As a result, when the workpiece 40 is processed by the processing machine 12, the possibility of a processing failure in which the actual shape of the manufactured shim 20 greatly deviates from the target shape is reduced.

  Furthermore, according to the present embodiment, the workpiece 40 is made to be part of the shim 20 while allowing the second tool 32 to partially enter the thickness portion of the double-sided adhesive tape 80 during trimming. While dividing | segmenting into an excess part, the 2nd tool 32 is prevented not only from contacting the surface of the pallet 70 but from separating the double-sided adhesive tape 80.

  As a result, according to the present embodiment, the trimming process reliably prevents the second tool 32 from damaging the workpiece 40, while the workpiece 40 is in spite of its manufacturing variation and assembly variation. , It is guaranteed that the shim 20 is divided into a part and an extra part.

  Thanks to this reliable division, the operator takes out the pallet 70 together with the workpiece 40 from the processing machine 12 and then leaves the double-sided adhesive tape 80 on the pallet 70 from the top surface of the pallet 70, and a plurality of shims. It is also possible to perform an additional operation of separating 20 one by one from another adjacent shim 20 without peeling the other adjacent shim 20. Thereby, it becomes easy to improve work efficiency, maintaining processing quality.

  As described above, some of the embodiments of the present invention have been described in detail with reference to the drawings. However, these are exemplifications, and are based on the knowledge of those skilled in the art including the aspects described in the section of [Summary of the Invention]. The present invention can be implemented in other forms with various modifications and improvements.

Claims (5)

By processing the workpiece by moving the tool relative to the plate-like workpiece in the processing machine, the tool is inserted into the gap to fill the planar gap existing between the two members assembled together. A shim production method for producing a shim,
The workpiece has a surface on which surface processing is performed and a back surface on which the surface processing is not performed.
Attach the workpiece to the surface of the pallet with the support layer on the back of the workpiece,
With the pallet mounted on the processing machine with the workpiece mounted,
In the processing machine, the surface processing and trimming processing are performed on the workpiece ,
During the trimming process, the tip of the tool passes through the workpiece in the thickness direction and reaches the inside of the support layer, but does not reach the surface of the pallet. A shim manufacturing method for controlling the position in the thickness direction and thereby manufacturing the shim as a part of the workpiece.   The tool forms a bottomless groove completely penetrating in the thickness direction in the workpiece, whereby the tool divides the workpiece into a part constituting the shim and an extra part. On the other hand, the shim manufacturing method according to claim 1, wherein a bottomed groove that penetrates only partially in the thickness direction is formed in the support layer.   The shim manufacturing method according to claim 1, wherein the shim is a solid shim including a single layer made of metal, synthetic resin, or composite material.   The shim manufacturing method according to claim 1 or 2, wherein the shim is a laminate shim in which a plurality of layers made of metal, synthetic resin, or composite material are laminated so as to be peelable from each other.   A program executed by a computer to carry out the method according to claim 1.

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