JP6805600B2 - Diagnostic equipment, diagnostic systems, diagnostic methods and programs - Google Patents

Description

The present invention relates to diagnostic devices, diagnostic systems, diagnostic methods and programs.

When machine tools such as drilling machines, milling machines, lathes or grinders are controlled by the NC (Numerical Control) system to perform metal processing, consumables such as tools (drills, end mills, bite tips, or grindstones) and bearings A microphone, an acceleration sensor, an AE (Acoustic Emission) sensor, etc. are attached to a machine tool or a work object (workpiece) to know the replacement guideline, and the detected data (acoustic data, acceleration data, or AE wave). There is known a technique for diagnosing machine tool operation and estimating tool wear state based on the above.

In estimating the wear state of such a tool, there are cases where it is desired to know that a consumable item such as a tool or a bearing has been replaced. For example, it is a case where the data accumulated every day is divided into units for which tools are exchanged and used as learning data (teacher data) for machine learning or verification data to improve the estimation algorithm.

In addition, the operator calculates the total movement distance of the tool by multiplying the number of times of machining by the machining operation distance of the tool when machining one work, and uses it as a guideline for the time to replace the tool or improves the process. In some cases, even if the type of tool (same material, same number of blades, etc.) is the same, the blades of manufacturers with a long average total movement distance are reviewed. For this reason, there are many cases where the NC system is set so as to count up the number of times of processing each time one work is processed.

As a technique for estimating the wear state of the tool during the machining process as described above, an AE sensor mounted on or near the tool of the machine tool, an amplifier circuit that amplifies the output of the AE sensor to an appropriate level, and an amplifier circuit. A bandpass filter provided on the output side of an amplifier circuit and passing a frequency component that has a strong correlation with tool wear, and a DC conversion circuit that rectifies and smoothes the bandpass filter output to obtain a DC signal. In machining, a tool wear degree detecting device provided with a signal extraction means for extracting a DC signal obtained from a DC circuit during a specific machining of 1 as a tool wear degree signal has been proposed (Patent Document). 1).

However, with the technique described in Patent Document 1, although it is possible to detect the degree of wear of the tool, it is not possible to automatically detect that the tool has been replaced, so that the timing at which the operator replaces the tool You have to manually record with and manually reset the number of machining. Therefore, in order to prevent such manual work from being forgotten, the operation manual becomes complicated, and there is a problem that the work time after tool replacement increases.

The present invention has been made in view of the above problems, and an object of the present invention is to provide a diagnostic device, a diagnostic system, a diagnostic method, and a program capable of reducing post-work work on a tool.

In order to solve the above-mentioned problems and achieve the object, the present invention has a first acquisition unit that acquires detection information of the physical amount detected from a detection unit that detects the physical amount of the tool of the target device, and the first acquisition unit. A calculation unit that calculates the degree of wear of the tool from the detection information acquired by the acquisition unit, and a calculation unit that calculates the degree of wear during the previous machining operation after the start of the machining operation after the target device is stopped. When the first determination unit that determines whether or not the calculated degree of wear satisfies a predetermined condition and the first determination unit determines that the predetermined condition is satisfied, work is performed on the tool. Acquires a writing unit that writes to the storage unit to indicate that the device has been damaged, and a plurality of context information determined for each type of operation of the tool of the target device, and context information corresponding to the current operation of the tool. A third acquisition unit and a second determination unit that determines the operating state of the target device from the context information acquired by the third acquisition unit are provided , and the first determination unit stops the target device. After that, after the second determination unit determines that the target device has started the machining operation, it is determined whether or not the predetermined condition is satisfied .

According to the present invention, it is possible to reduce the work after the work on the tool.

FIG. 1 is a diagram showing an example of the overall configuration of the diagnostic system according to the first embodiment. FIG. 2 is a diagram showing an example of the hardware configuration of the processing machine of the first embodiment. FIG. 3 is a diagram showing an example of the hardware configuration of the diagnostic apparatus according to the first embodiment. FIG. 4 is a diagram showing an example of the configuration of the functional block of the diagnostic system according to the first embodiment. FIG. 5 is a diagram illustrating a change in the degree of wear of the tool due to the machining operation. FIG. 6 is a diagram for explaining that it is determined that the tool has been replaced due to a large decrease in the degree of wear. FIG. 7 is a diagram for explaining that it is determined that the tool has been replaced due to a large increase in the degree of wear. FIG. 8 is a flowchart showing an example of an operation of determining the replacement of the tool based on the change in the degree of wear in the first embodiment. FIG. 9 is a diagram showing an example of the configuration of the functional block of the diagnostic system according to the second embodiment. FIG. 10 is a flowchart showing an example of an operation of determining the replacement of the tool based on the change in the degree of wear in the second embodiment.

Hereinafter, embodiments of a diagnostic apparatus, a diagnostic system, a diagnostic method, and a program according to the present invention will be described in detail with reference to the drawings. Further, the present invention is not limited to the following embodiments, and the components in the following embodiments include those easily conceived by those skilled in the art, substantially the same, and so-called equal ranges. Included. Furthermore, various omissions, substitutions, changes and combinations of components can be made without departing from the gist of the following embodiments.

[First Embodiment]
(Configuration of diagnostic system)
FIG. 1 is a diagram showing an example of the overall configuration of the diagnostic system according to the first embodiment. The configuration of the diagnostic system 1 according to the present embodiment will be described with reference to FIG.

As shown in FIG. 1, the diagnostic system 1 includes a diagnostic device 100 and a sensor 57. The diagnostic device 100 is a device that diagnoses abnormalities in the operation of the processing machine 200. The sensor 57 detects a physical quantity such as vibration or sound generated by a tool such as a drill, an end mill, a tool tip, or a grindstone installed in the processing machine 200, and uses the detected physical quantity information as detection information (sensor data) as a diagnostic device. Output to 100. The sensor 57 is composed of, for example, a microphone, an acceleration sensor, an AE sensor, or the like.

The processing machine 200 is a machine tool that uses a tool to perform processing such as cutting, grinding, or polishing on a processing object. The processing machine 200 is an example of a target device to be diagnosed by the diagnostic device 100.

The diagnostic device 100 and the processing machine 200 are communicably connected to each other. The diagnostic device 100 and the processing machine 200 may be connected in any connection form. For example, the diagnostic device 100 and the processing machine 200 are connected by a dedicated line, a wired network such as a wired LAN (Local Area Network), a wireless network, or the like.

The number of sensors 57 may be arbitrary. Further, a plurality of sensors 57 for detecting the same physical quantity may be provided, or a plurality of sensors 57 for detecting different physical quantities may be provided.

Further, the sensor 57 may be provided in advance in the processing machine 200, or may be attached to the processing machine 200 which is a completed machine later.

(Hardware configuration of processing machine)
FIG. 2 is a diagram showing an example of the hardware configuration of the processing machine of the first embodiment. The hardware configuration of the processing machine 200 of the present embodiment will be described with reference to FIG.

As shown in FIG. 2, the processing machine 200 is driven by a CPU (Central Processing Unit) 51, a ROM (Read Only Memory) 52, a RAM (Random Access Memory) 53, a communication I / F (interface) 54, and the like. The control circuit 55 and the control circuit 55 are connected by a bus 58. Further, as described above, the sensor 57 is installed in the processing machine 200.

The CPU 51 controls the entire processing machine 200. For example, the CPU 51 controls the operation of the entire processing machine 200 and realizes a processing function by executing a program stored in the ROM 52 or the like with the RAM 53 as a work area (work area).

The communication I / F 54 is an interface for communicating with an external device such as the diagnostic device 100. The drive control circuit 55 is a circuit that controls the drive of the motor 56. The motor 56 drives tools used for machining drills, cutters, tables, and the like. The sensor 57 detects a physical quantity that changes according to the operation of the processing machine 200, and outputs the detection information to the diagnostic apparatus 100.

(Hardware configuration of diagnostic device)
FIG. 3 is a diagram showing an example of the hardware configuration of the diagnostic apparatus according to the first embodiment. The hardware configuration of the diagnostic apparatus 100 according to the present embodiment will be described with reference to FIG.

As shown in FIG. 3, in the diagnostic device 100, the CPU 61, the ROM 62, the RAM 63, the communication I / F64, the sensor I / F65, the input / output I / F66, and the auxiliary storage device 67 are on the bus 68. It has a connected configuration.

The CPU 61 controls the entire diagnostic device 100. The CPU 61 controls the operation of the entire diagnostic device 100 and realizes a diagnostic function by executing a program stored in the ROM 62 or the like with the RAM 63 as a work area (work area), for example.

The communication I / F64 is an interface for communicating with an external device such as a processing machine 200. The sensor I / F65 is an interface for receiving detection information from the sensor 57.

The input / output I / F 66 is an interface for connecting various devices (for example, the input device 66a and the display 66b) and the bus 68.

The input device 66a is an input device such as a mouse or keyboard for inputting characters and numbers, selecting various instructions, and performing operations such as moving a cursor.

The display 66b is a display device such as an LCD (Liquid Crystal Display), a plasma display, or an organic EL (Electro-Lumisense) display that displays various information such as cursors, menus, windows, characters, and images.

The auxiliary storage device 67 includes setting information of the diagnostic device 100, detection information received from the processing machine 200, recording data of the processing state of the processing machine 200, adjustment and replacement of tools, an OS (Operating System), an application program, and an application program. It is a non-volatile storage device such as an HDD (Hard Disk Drive), an SSD (Solid State Drive), or an EEPROM (Electrically Erasable Programmable Read-Only Memory) that stores various data. The auxiliary storage device 67 is provided in the diagnostic device 100, but is not limited to this, and may be, for example, a storage device installed outside the diagnostic device 100, or the diagnostic device. It may be a storage device provided with a server device capable of data communication with 100.

(Configuration and operation of functional blocks of diagnostic system)
FIG. 4 is a diagram showing an example of the configuration of the functional block of the diagnostic system according to the first embodiment. FIG. 5 is a diagram illustrating a change in the degree of wear of the tool due to the machining operation. FIG. 6 is a diagram for explaining that it is determined that the tool has been replaced due to a large decrease in the degree of wear. The configuration and operation of the functional blocks of the diagnostic system according to the present embodiment will be described with reference to FIGS. 4 to 6. At the same time, the configuration and operation of the functional blocks of the processing machine 200 will be described.

As shown in FIG. 4, the processing machine 200 includes a numerical control unit 201, a communication control unit 202, a drive control unit 203, a drive unit 204, and a detection unit 211.

The numerical control unit 201 is a functional unit that executes machining by the drive unit 204 by numerical control (NC: Numerical Control). For example, the numerical control unit 201 generates and outputs numerical control data for controlling the operation of the drive unit 204. Further, the numerical control unit 201 outputs the context information to the communication control unit 202. Here, the context information is a plurality of information defined for each type of operation of the processing machine 200. The context information includes, for example, information for identifying the drive unit 204, the operating state of the drive unit 204, the rotation speed of the drive unit 204, the rotation speed of the drive unit 204, the load related to the drive unit 204, the size of the drive unit 204, and the size of the drive unit 204. , Information indicating the cumulative usage time from the start of use of the drive unit 204 and the like.

For example, the numerical control unit 201 transmits context information indicating the current operation of the processing machine 200 to the diagnostic apparatus 100 via the communication control unit 202. When machining an object to be machined, the numerical control unit 201 changes the type of drive unit 204 to be driven and the drive state (rotation speed, rotation speed, etc.) of the drive unit 204 according to the machining process. It is assumed that the numerical control unit 201 counts the number of times of machining for each tool driven by the drive unit 204 in the internal memory or the like. Every time the type of operation is changed, the numerical control unit 201 sequentially transmits the context information corresponding to the changed type of operation and the information on the number of times of machining for each tool to the diagnostic apparatus 100 via the communication control unit 202. .. The information on the number of times of processing may be included in the context information. The numerical control unit 201 is realized by, for example, a program running on the CPU 51 shown in FIG.

The communication control unit 202 is a functional unit that controls communication with an external device such as the diagnostic device 100. For example, the communication control unit 202 transmits the context information corresponding to the current operation and the information on the number of times of machining for each tool to the diagnostic apparatus 100. The communication control unit 202 is realized by, for example, a communication I / F 54 shown in FIG. 2 and a program running on the CPU 51.

The drive control unit 203 is a functional unit that drives and controls the drive unit 204 based on the numerical control data obtained by the numerical control unit 201. The drive control unit 203 is realized by, for example, the drive control circuit 55 shown in FIG.

The drive unit 204 is a functional unit that is the target of drive control by the drive control unit 203. The drive unit 204 drives the tool under the control of the drive control unit 203. The drive unit 204 is an actuator that is drive-controlled by the drive control unit 203, and is realized by, for example, the motor 56 shown in FIG.

The detection unit 211 detects a physical quantity such as vibration or sound generated by a tool such as a drill, an end mill, a tool tip, or a grindstone installed in the processing machine 200, and diagnoses the detected physical quantity information as detection information (sensor data). This is a functional unit that outputs to the device 100. The detection unit 211 is realized by the sensor 57 shown in FIG.

The numerical control unit 201 and the communication control unit 202 shown in FIG. 4 may be realized by causing the CPU 51 shown in FIG. 2 to execute a program, that is, by software, or by hardware such as an IC (Integrated Circuit). It may be realized, or it may be realized by using software and hardware together.

As shown in FIG. 4, the diagnostic apparatus 100 includes a communication control unit 101, a detection information receiving unit 102 (first acquisition unit), a processing information acquisition unit 103 (third acquisition unit), and a processing number acquisition unit 104 (! Second acquisition unit), calculation unit 105, operation determination unit 106 (second determination unit), exchange determination unit 107 (first determination unit), storage unit 108, input unit 109, and display control unit 110. And a display unit 111, and a result writing unit 112 (an example of a writing unit).

The communication control unit 101 is a functional unit that controls communication with an external device such as a processing machine 200. The communication control unit 101 is realized by, for example, the communication I / F64 shown in FIG. 3 and a program that operates on the CPU 61. The communication control unit 101 includes a reception unit 101a and a transmission unit 101b.

The receiving unit 101a is a functional unit that receives context information and information on the number of times of machining for each tool from the numerical control unit 201 of the machining machine 200 via the communication control unit 202. The transmission unit 101b is a functional unit that transmits various information to an external device such as the processing machine 200.

The detection information receiving unit 102 is a functional unit that receives detection information from the detection unit 211 installed in the processing machine 200. The detection information receiving unit 102 is realized by, for example, a program that operates on the sensor I / F65 and the CPU 61 shown in FIG.

The processing information acquisition unit 103 is a functional unit that acquires context information (machining information) received by the receiving unit 101a from the processing machine 200. The processing information acquisition unit 103 is realized by, for example, a program running on the CPU 61 shown in FIG.

The machining count acquisition unit 104 is a functional unit that acquires the machining count for each tool received by the receiving unit 101a from the machining machine 200. The processing number acquisition unit 104 is realized by, for example, a program running on the CPU 61 shown in FIG. The machining count acquisition unit 104 is not limited to acquiring the machining count from the machining machine 200 received by the reception unit 101a. For example, as will be described later, the tool has been replaced by the replacement determination unit 107. When is determined, the number of machining may be reset and the number of machining may be counted up for each machining operation of the machining machine 200 determined by the operation determination unit 106.

Based on the detection information (sensor data) of the detection unit 211 received by the detection information reception unit 102, the calculation unit 105 wears the tool such as the drill, end mill, tool tip, or grindstone of the processing machine 200 (wear). It is a functional part that calculates the degree). Here, the degree of wear is a value indicating how long the wear is with respect to the diameter of a tool such as a new drill or grindstone, for example. Specifically, the calculation unit 105 extracts a feature amount such as the maximum amplitude of a specific frequency subjected to Fourier transform or the vibration time from the detection information received by the detection information receiving unit 102, and calculates the feature amount. Use to calculate the degree of wear. As shown in FIG. 5A, the degree of wear is a value that tends to increase as the number of times of processing is increased. However, as shown in FIG. 5B, before and after the degree of wear is stably switched, the feature amount that is the basis for calculating the degree of wear can take a random value with a certain width. When the degree of wear is calculated based on this feature amount, the numerical value may vibrate for a short period until the value is stably switched. In other words, the degree of wear is a value that increases as a whole, but the determination result may go up or down by one step in a specific period. It should be noted that a filter may be applied to prevent such an unstable determination result.

The calculation unit 105 is realized by, for example, a program running on the CPU 61 shown in FIG.

The motion determination unit 106 is a function unit that determines the operation state (which tool is performing what kind of operation, etc.) of the processing machine 200 based on the context information received by the reception unit 101a. The operation determination unit 106 is realized by, for example, a program that operates on the CPU 61 shown in FIG.

The replacement determination unit 107 is a functional unit that determines whether or not the tool has been replaced based on the change in the degree of wear of the tool calculated by the calculation unit 105.

For example, in the example shown in FIG. 6, the number of times of processing is around 3000, and the degree of wear is extremely reduced from 7 to 1. In this way, it can be determined that the tool has been replaced at the timing when the degree of wear decreases. Further, in the example shown in FIG. 7, the number of times of processing is around 1500 times, and the degree of wear is extremely increased from 3 to 6. In this way, it can be determined that the tool has been replaced at the timing when the degree of wear increases. For example, the replacement determination unit 107 determines that the tool has been replaced when the wear degree of the tool calculated by the calculation unit 105 changes (decreases or rises) by a predetermined threshold value or more from the wear degree at the time of the previous machining. And it is sufficient.

When the tool is replaced, the degree of wear should theoretically be 0. Therefore, the replacement determination unit 107 determines that the tool has been replaced when the degree of wear of the tool calculated by the calculation unit 105 is 0. It may be the one to do. Here, it is assumed that the degree of wear of 0 does not strictly indicate 0, but includes the fact that it is a minute value that can be regarded as 0.

Further, the replacement determination unit 107 may not only determine whether or not the tool has been replaced, but may also determine whether or not other work such as adjustment of the tool has been performed based on the change in the degree of wear. The adjustment of the tool is, for example, adjusting the mounting position of the tool according to the wear state of the tool. In this case, for example, the replacement determination unit 107 replaces the tool when the wear degree of the tool calculated by the calculation unit 105 changes (decreases or rises) by a predetermined first threshold value or more from the wear degree at the time of the previous machining. If it is determined that the tool has been worn and the degree of wear changes between the second threshold value (<first threshold value) and less than the first threshold value, it may be determined that the tool has been adjusted.

The exchange determination unit 107 is realized by, for example, a program that operates on the CPU 61 shown in FIG.

The storage unit 108 is a functional unit that stores various information necessary for the diagnostic function of the diagnostic apparatus 100, as well as recorded data such as the machining state of the machining machine 200, adjustment and replacement of tools, and the like. The storage unit 108 is realized by, for example, the auxiliary storage device 67 shown in FIG.

The input unit 109 is a functional unit for inputting characters and numbers, selecting various instructions, moving the cursor, and the like. The input unit 109 is realized by the input device 66a shown in FIG.

The display control unit 110 is a functional unit that controls the display operation of the display unit 111. The display control unit 110 is realized by, for example, a program that operates on the CPU 61 shown in FIG.

The display unit 111 is a functional unit that displays various information according to the control by the display control unit 110. The display unit 111 is realized by the display 66b shown in FIG.

The result writing unit 112 is a functional unit that writes the determination result as recording data to the storage unit 108 when it is determined by the exchange determination unit 107 that the tool has been exchanged. The result writing unit 112 stores, for example, the recorded data in association with the detection information corresponding to the final wear degree determined to have been exchanged by the exchange determination unit 107 (for example, with a time stamp or the like). You may. As described above, when the replacement determination unit 107 determines not only the replacement of the tool but also the adjustment, the result writing unit 112 may write the determination result as recording data in the storage unit 108.

The result writing unit 112 is realized by, for example, a program running on the CPU 61 shown in FIG.

The communication control unit 101, the detection information receiving unit 102, the processing information acquisition unit 103, the processing number acquisition unit 104, the calculation unit 105, the operation determination unit 106, the exchange determination unit 107, the display control unit 110, and the result shown in FIG. As described above, the writing unit 112 may be realized by having the CPU 61 shown in FIG. 3 execute the program, that is, by software, or by hardware such as an IC (Integrated Circuit). It may be realized by using software and hardware together.

Further, each functional unit of the processing machine 200 and the diagnostic apparatus 100 shown in FIG. 4 conceptually shows a function, and is not limited to such a configuration. For example, a plurality of functional units shown as independent functional units in FIG. 4 may be configured as one functional unit. On the other hand, the function of one functional unit in FIG. 4 may be divided into a plurality of functions and configured as a plurality of functional units.

(Operation to judge tool change)
FIG. 8 is a flowchart showing an example of an operation of determining the replacement of the tool based on the change in the degree of wear in the first embodiment. The operation of determining the tool change by the diagnostic system 1 according to the present embodiment will be described with reference to FIG.

<Step S11>
The processing information acquisition unit 103 of the diagnostic apparatus 100 acquires the context information (processing information) received by the receiving unit 101a from the processing machine 200. Then, the process proceeds to step S12.

<Step S12>
The operation determination unit 106 of the diagnostic apparatus 100 determines whether or not the processing state of the processing machine 200 has changed from the processing stop to the processing in progress based on the context information acquired by the processing information acquisition unit 103. If the process is in progress from the processing stop (step S12: Yes), the process proceeds to step S13, and if not (step S12: No), the process proceeds to step S14.

<Step 13>
The detection information receiving unit 102 starts (restarts) the operation of receiving (acquiring) the detection information from the detection unit 211 installed in the processing machine 200. Then, the process proceeds to step S15.

<Step S14>
The operation determination unit 106 further determines, based on the context information acquired by the machining information acquisition unit 103, whether or not the machining state of the machining machine 200 has been stopped during machining. If the processing is stopped during processing (step S14: Yes), the process proceeds to step S20, and if not (step S14: No), the process returns to step S11.

<Step S15>
The calculation unit 105 of the diagnostic apparatus 100 extracts a feature amount from the detection information received by the detection information receiving unit 102, and calculates the degree of wear using the feature amount. Then, the process proceeds to step S16.

<Step S16>
The replacement determination unit 107 of the diagnostic apparatus 100 acquires the degree of wear stored in the storage unit 108 and calculated by the calculation unit 105 at the time of the previous machining. The initial value of the degree of wear stored in the storage unit 108 may be, for example, "0" (minimum wear degree). Then, the process proceeds to step S17.

<Step S17>
The replacement determination unit 107 stops the machining operation of the processing machine 200 from the change between the wear degree (current wear degree) calculated by the calculation unit 105 in step S15 and the wear degree at the time of the previous machining acquired in step S16. Determine if the tool has been replaced inside. Specifically, the replacement determination unit 107 determines that the tool has been replaced, for example, when the current wear degree changes (decreases or rises) by a predetermined threshold value (for example, "2") or more from the wear degree at the time of the previous machining. (Step S17: Yes), and the process proceeds to step S18. On the other hand, if the current degree of wear does not change (decrease or increase) by a predetermined threshold value or more from the degree of wear at the time of the previous machining, the replacement determination unit 107 determines that the tool has not been replaced (step S17: No). , Step S19.

<Step S18>
When the replacement determination unit 107 determines that the tool has been replaced, the result writing unit 112 of the diagnostic device 100 writes the determination result as recording data in the storage unit 108. Then, the process proceeds to step S19.

<Step S19>
The replacement determination unit 107 updates the wear degree at the time of the previous machining stored in the storage unit 108 to the wear degree (current wear degree) calculated by the calculation unit 105 in step S15. Then, the process returns to step S11.

<Step S20>
The detection information receiving unit 102 stops the operation of receiving (acquiring) the detection information from the detection unit 211 installed in the processing machine 200. Then, the process proceeds to step S21.

<Step S21>
Since it is determined in step S14 that the machining state of the machining machine 200 has stopped machining from the middle of machining, the machining number acquisition unit 104 determines that one machining operation has been completed, and uses its own device (diagnosis device 100). Count up the number of processed processes. Specifically, the machining number acquisition unit 104 may be counted up on the processing machine 200 side and acquire the machining number received by the receiving unit 101a, or may be managed by its own device (diagnosis device 100). The number of times of processing may be directly counted up. Then, the process returns to step S11.

According to the flow of steps S11 to S21 described above, the operation of determining the tool change by the diagnostic system 1 is performed. In the flow shown in FIG. 8 above, it is shown that the degree of wear is calculated in step S15, that is, when it is determined in step S12 that machining has started from stopping machining. However, this does not mean that the degree of wear is calculated only at this timing, and the degree of wear is calculated by the calculation unit 105 at all times or at predetermined intervals during the machining operation of the processing machine 200.

As described above, when the degree of wear calculated at the time of resuming machining after the machining of the machining machine 200 is stopped satisfies a predetermined condition, it is determined that the work (replacement or adjustment, etc.) has been performed on the tool, and the determination result is recorded. It is supposed to be stored as data. This makes it possible to automatically detect that work (replacement or adjustment, etc.) has been performed on the tool, and the fact that work has been performed can be stored as record data, so it is necessary to manually record it. It is possible to reduce the work after the work (replacement or adjustment, etc.) on the tool. In addition, since it is automatically recorded that work (replacement or adjustment, etc.) has been performed on the tool, the detection information is divided for each work unit of the tool without forgetting to record, and the learning data of machine learning (teacher data). ) Or as verification data, it is possible to improve the estimation (calculation) of the degree of wear and the diagnostic processing of the operation of the processing machine 200.

Further, as described above, in the replacement determination unit 107, for example, when the current wear degree changes (decreases or rises) by a predetermined threshold value (for example, “2”) or more from the wear degree at the time of the previous machining, the tool is replaced. It is judged that it was. That is, since the threshold value is determined based on the absolute value of the difference in wear degree, for example, even when a tool having a wear degree of "3" is replaced with a tool having a wear degree of "6", the tool is replaced. Can be detected.

[Second Embodiment]
The diagnostic system according to the second embodiment will be described focusing on the differences from the diagnostic system according to the first embodiment. In the first embodiment, the operation of recording the work done on the tool in some form has been described. In the present embodiment, when a replacement work is performed among the operations on the tool, an operation indicating that the tool has been replaced by automatically resetting the number of times of machining will be described. The overall configuration of the diagnostic system and the hardware configuration of the processing machine 200 and the diagnostic apparatus are the same as those described in the first embodiment.

(Configuration and operation of functional blocks of diagnostic system)
FIG. 9 is a diagram showing an example of the configuration of the functional block of the diagnostic system according to the second embodiment. The configuration and operation of the functional blocks of the diagnostic system according to the present embodiment will be described with reference to FIG. The configuration and operation of the functional block of the processing machine 200 are the same as those described in the first embodiment.

As shown in FIG. 9, the diagnostic apparatus 100a according to the present embodiment includes a communication control unit 101, a detection information receiving unit 102 (first acquisition unit), a processing information acquisition unit 103 (third acquisition unit), and processing. The number of times acquisition unit 104 (second acquisition unit), the calculation unit 105, the operation determination unit 106 (second determination unit), the exchange determination unit 107 (first determination unit), the storage unit 108, and the input unit 109. , A display control unit 110, a display unit 111, and a reset unit 113 (an example of a writing unit). The communication control unit 101, the detection information receiving unit 102, the processing information acquisition unit 103, the calculation unit 105, the operation determination unit 106, the exchange determination unit 107, the storage unit 108, the input unit 109, the display control unit 110, and the display unit 111. The operation of is the same as the content described in the first embodiment.

The machining count acquisition unit 104 is a functional unit that acquires the machining count for each tool received by the receiving unit 101a from the machining machine 200. The processing number acquisition unit 104 is realized by, for example, a program running on the CPU 61 shown in FIG. The machining count acquisition unit 104 is not limited to acquiring the machining count from the machining machine 200 received by the reception unit 101a. For example, as will be described later, the machining machine 200 determined by the operation determination unit 106. The number of times of machining may be counted up for each machining operation of.

The reset unit 113 is a functional unit that resets the number of machining operations managed by the own device (diagnosis device 100a) when the replacement determination unit 107 determines that the tool has been replaced. Specifically, the reset unit 113 resets and updates the number of times of processing stored in the storage unit 108 to "0". Further, the reset unit 113 transmits a reset request for resetting the number of times of machining managed by the machining machine 200 to the machining machine 200 via the transmission unit 101b. The reset unit 113 is realized by, for example, a program running on the CPU 61 shown in FIG.

The communication control unit 101, the detection information receiving unit 102, the processing information acquisition unit 103, the processing number acquisition unit 104, the calculation unit 105, the operation determination unit 106, the exchange determination unit 107, the display control unit 110, and the reset shown in FIG. As described above, the unit 113 causes the CPU 61 shown in FIG. 3 to execute the program, that is, it may be realized by software, it may be realized by hardware such as IC, or software and hardware may be used in combination. It may be realized by

Further, each functional unit of the processing machine 200 and the diagnostic apparatus 100a shown in FIG. 9 conceptually shows the function, and is not limited to such a configuration. For example, a plurality of functional units shown as independent functional units in FIG. 9 may be configured as one functional unit. On the other hand, the function of one functional unit in FIG. 9 may be divided into a plurality of functions and configured as a plurality of functional units.

(Operation to judge tool change)
FIG. 10 is a flowchart showing an example of an operation of determining the replacement of the tool based on the change in the degree of wear in the second embodiment. The operation of determining the tool change by the diagnostic system according to the present embodiment will be described with reference to FIG.

<Step S31>
The processing information acquisition unit 103 of the diagnostic apparatus 100a acquires the context information (processing information) received by the receiving unit 101a from the processing machine 200. Then, the process proceeds to step S32.

<Step S32>
The operation determination unit 106 of the diagnostic apparatus 100a determines whether or not the processing state of the processing machine 200 has changed from processing stop to processing based on the context information acquired by the processing information acquisition unit 103. If the process is in progress from the processing stop (step S32: Yes), the process proceeds to step S33, and if not (step S32: No), the process proceeds to step S34.

<Step 33>
The detection information receiving unit 102 starts (restarts) the operation of receiving (acquiring) the detection information from the detection unit 211 installed in the processing machine 200. Then, the process proceeds to step S35.

<Step S34>
The operation determination unit 106 further determines, based on the context information acquired by the machining information acquisition unit 103, whether or not the machining state of the machining machine 200 has been stopped during machining. If the processing is stopped from the middle of processing (step S34: Yes), the process proceeds to step S41, and if not (step S34: No), the process returns to step S31.

<Step S35>
The calculation unit 105 of the diagnostic apparatus 100a extracts a feature amount from the detection information received by the detection information receiving unit 102, and calculates the degree of wear using the feature amount. Then, the process proceeds to step S36.

<Step S36>
The replacement determination unit 107 of the diagnostic apparatus 100a acquires the degree of wear stored in the storage unit 108 and calculated by the calculation unit 105 at the time of the previous machining. Then, the process proceeds to step S37.

<Step S37>
The replacement determination unit 107 stops the machining operation of the machining machine 200 from the change between the wear degree (current wear degree) calculated by the calculation unit 105 in step S35 and the wear degree at the time of the previous machining acquired in step S36. Determine if the tool has been replaced inside. Specifically, the replacement determination unit 107 determines that the tool has been replaced, for example, when the current degree of wear changes (decreases or rises) by a predetermined threshold value (for example, "2") or more from the degree of wear during the previous machining. (Step S37: Yes), and the process proceeds to step S38. On the other hand, if the current degree of wear does not change (decrease or increase) by a predetermined threshold value or more from the degree of wear at the time of the previous machining, the replacement determination unit 107 determines that the tool has not been replaced (step S37: No). , Step S40.

<Step S38>
When the replacement determination unit 107 determines that the tool has been replaced, the reset unit 113 of the diagnostic apparatus 100a processes a reset request for resetting the number of times of machining managed by the processing machine 200 via the transmission unit 101b. It is transmitted to the machine 200. However, in this case, in order to reset the number of machining times managed by the machining machine 200, the machining machine 200 receives a stop command in the program that realizes the numerical control unit 201 or the like of the machining machine 200. It is premised that it is stipulated to reset the number of machining that is being managed. Further, it is desirable that the number of times of processing managed by the processing machine 200 is displayed on a display device or the like on the processing machine 200 side. Thereby, the operator of the processing machine 200 can confirm that the numerical control unit 201 of the processing machine 200 has reset the number of times of processing in response to the reset request from the diagnostic device 100a after the tool is replaced. Then, the process proceeds to step S39.

<Step S39>
When the replacement determination unit 107 determines that the tool has been replaced, the reset unit 113 resets the number of machining operations managed by its own device (diagnosis device 100a). Further, it is desirable that the display control unit 110 display the number of times of processing managed by the diagnostic apparatus 100a on the display unit 111. As a result, the operator of the processing machine 200 confirms that the number of times of machining displayed on the display unit 111 has been reset after the replacement of the tool, so that the replacement of the tool is recognized on the diagnostic device 100a side. You can check. Then, the process proceeds to step S40.

<Step S40>
The replacement determination unit 107 updates the wear degree at the time of the previous machining stored in the storage unit 108 to the wear degree (current wear degree) calculated by the calculation unit 105 in step S35. Return to step S31.

<Step S41>
The detection information receiving unit 102 stops the operation of receiving (acquiring) the detection information from the detection unit 211 installed in the processing machine 200. Then, the process proceeds to step S42.

<Step S42>
Since it is determined in step S34 that the machining state of the machining machine 200 has stopped machining from the middle of machining, the machining number acquisition unit 104 determines that one machining operation has been completed, and uses its own device (diagnosis device 100a). Count up the number of processed processes. Specifically, the machining number acquisition unit 104 may be counted up on the processing machine 200 side and acquire the machining number received by the receiving unit 101a, or may be managed by its own device (diagnosis device 100a). The number of times of processing may be directly counted up. In this case, the machining count acquisition unit 104 writes (updates) the count-up machining count in the storage unit 108. Further, it is desirable that the display control unit 110 display the number of times of processing managed by the diagnostic apparatus 100a on the display unit 111. As a result, the operator of the processing machine 200 confirms that the number of processing times displayed on the display unit 111 is counted up, so that the diagnostic apparatus 100a recognizes the completion of the processing operation of the processing machine 200. You can confirm that you are there. Then, the process returns to step S31.

According to the flow of steps S31 to S42 described above, the operation of determining the tool change by the diagnostic system according to the present embodiment is performed. In the flow shown in FIG. 10 above, it is shown that the degree of wear is calculated in step S35, that is, when it is determined in step S32 that machining has started from machining stop. However, this does not mean that the degree of wear is calculated only at this timing, and the degree of wear is calculated by the calculation unit 105 at all times or at predetermined intervals during the machining operation of the processing machine 200.

As described above, if the degree of wear calculated at the time of resuming machining after the machining of the machining machine 200 is stopped and the predetermined condition is satisfied, it is determined that the tool has been replaced, and the number of machining times managed by the own device (diagnostic device 100a) Is supposed to be reset. Further, the reset unit 113 transmits a reset request for resetting the number of times of processing managed by the processing machine 200 to the processing machine 200 via the transmission unit 101b. As a result, it becomes possible to automatically detect that the tool has been replaced, and the number of machining operations managed by each of the diagnostic device 100a and the machining machine 200 can be automatically reset, so that it is necessary to perform the resetting work manually. It is possible to reduce the work after changing the tool.

Further, by displaying the number of times of machining managed by the diagnostic apparatus 100a on the display unit 111, the operator of the processing machine 200 confirms that the number of times of machining displayed on the display unit 111 is counted up for diagnosis. It can be confirmed that the completion of the machining operation of the machining machine 200 is recognized on the device 100a side, and it is confirmed that the number of machining times displayed on the display unit 111 has been reset after the tool is replaced. This makes it possible to confirm that the replacement of the tool has been recognized on the diagnostic device 100a side. Further, by displaying the number of times of machining on the display device of the machining machine 200, the operator of the machining machine 200 responds to the reset request from the diagnostic device 100a by the numerical control unit 201 of the machining machine 200 after the tool is replaced. , It can be confirmed that the number of times of machining has been reset.

The program executed by the diagnostic apparatus of each of the above-described embodiments is provided by being incorporated in a ROM or the like in advance.

The program executed by the diagnostic apparatus of each of the above-described embodiments is a file in an installable format or an executable format, and is a CD-ROM (Compact Disk Read Only Memory), a flexible disk (FD), or a CD-R (Compact Disk). -It may be configured to be recorded on a computer-readable recording medium such as a Recordable or a DVD (Digital Versail Disc) and provided as a computer program product.

Further, the program executed by the diagnostic apparatus of each of the above-described embodiments may be stored on a computer connected to a network such as the Internet and provided by downloading via the network. Further, the program executed by the diagnostic apparatus of each of the above-described embodiments may be configured to be provided or distributed via a network such as the Internet.

The program executed by the diagnostic apparatus of each of the above-described embodiments has a module configuration including the above-mentioned parts, and the actual hardware is such that the CPU (processor) reads the program from the ROM and executes the program. Each part is loaded on the main memory, and each part is generated on the main memory.

1 Diagnostic system 51 CPU
52 ROM
53 RAM
54 Communication I / F
55 Drive control circuit 56 Motor 57 Sensor 58 Bus 61 CPU
62 ROM
63 RAM
64 Communication I / F
65 Sensor I / F
66 I / O I / F
66a Input device 66b Display 67 Auxiliary storage device 68 Bus 100, 100a Diagnostic device 101 Communication control unit 101a Reception unit 101b Transmission unit 102 Detection information reception unit 103 Processing information acquisition unit 104 Processing count acquisition unit 105 Calculation unit 106 Operation judgment unit 107 Replacement Judgment unit 108 Storage unit 109 Input unit 110 Display control unit 111 Display unit 112 Result writing unit 113 Reset unit 200 Processing machine 201 Numerical control unit 202 Communication control unit 203 Drive control unit 204 Drive unit 211 Detection unit

Japanese Unexamined Patent Publication No. 60-151557

Claims (9)

The first acquisition unit that acquires the detection information of the physical quantity detected from the detection unit that detects the physical quantity of the tool of the target device, and
A calculation unit that calculates the degree of wear of the tool from the detection information acquired by the first acquisition unit, and
A first determination unit that determines whether or not the wear degree during the previous machining operation and the wear degree calculated by the calculation unit satisfy a predetermined condition after the machining operation is started after the target device is stopped. When,
When the first determination unit determines that the predetermined condition is satisfied, a writing unit that writes to the storage unit that the work has been performed on the tool, and a writing unit.
A third acquisition unit that acquires context information corresponding to the current operation of the tool among a plurality of context information defined for each type of operation of the tool of the target device.
A second determination unit that determines the operating state of the target device from the context information acquired by the third acquisition unit, and
Equipped with a,
The first determination unit is a diagnostic device that determines whether or not the predetermined condition is satisfied after the second determination unit determines that the target device has started a machining operation after the target device has stopped. .. When the absolute value of the difference between the degree of wear during the previous machining operation and the degree of wear calculated by the calculation unit is equal to or greater than a predetermined threshold value, the first determination unit determines the tool. The diagnostic device according to claim 1, wherein it is determined that the device has been replaced. The diagnostic device according to claim 1 or 2, wherein when the first determination unit determines that the work has been performed on the tool, the writing unit writes the determination result as record data in the storage unit. .. A second acquisition unit that acquires the number of times of machining by the tool from the target device, and
The diagnostic device according to claim 1 or 2, wherein when the first determination unit determines that the tool has been replaced, the writing unit resets the number of times of machining and writes the tool in the storage unit. A display control unit for displaying the number of times of processing acquired by the second acquisition unit on the display unit is further provided.
The diagnostic device according to claim 4, wherein the display control unit resets and displays the number of times of processing displayed on the display unit when the number of times of processing is reset by the writing unit. When the first determination unit determines that the tool has been replaced, the writing unit transmits a reset request for resetting the number of machining operations managed by the target device to the target device. Item 4. The diagnostic apparatus according to item 4. The diagnostic device according to any one of claims 1 to 6 .
With the detector
Diagnostic system with. The first acquisition step of acquiring the detection information of the physical quantity detected from the detection unit that detects the physical quantity of the tool of the target device, and
A calculation step for calculating the wear degree of the tool from the acquired detection information, and
A third acquisition step of acquiring context information corresponding to the current operation of the tool among a plurality of context information defined for each type of operation of the tool of the target device, and
The second determination step of determining the operating state of the target device from the acquired context information, and
After the target device is stopped, it is determined in the second determination step that the target device has started the machining operation, and then the degree of wear during the previous machining operation and the calculated degree of wear satisfy a predetermined condition. The first determination step to determine whether or not to satisfy,
When it is determined that the predetermined condition is satisfied, a writing step of writing to the storage unit indicating that the work has been performed on the tool, and a writing step.
Diagnostic method with. Computer,
The first acquisition unit that acquires the detection information of the physical quantity detected from the detection unit that detects the physical quantity of the tool of the target device, and
A calculation unit that calculates the degree of wear of the tool from the detection information acquired by the first acquisition unit, and
A first determination unit that determines whether or not the wear degree during the previous machining operation and the wear degree calculated by the calculation unit satisfy a predetermined condition after the machining operation is started after the target device is stopped. When,
When the first determination unit determines that the predetermined condition is satisfied, a writing unit that writes to the storage unit that the work has been performed on the tool, and a writing unit.
A third acquisition unit that acquires context information corresponding to the current operation of the tool among a plurality of context information defined for each type of operation of the tool of the target device.
A second determination unit that determines the operating state of the target device from the context information acquired by the third acquisition unit, and
And it is made to function,
The first determination unit is for determining whether or not the predetermined condition is satisfied after the second determination unit determines that the target device has started the machining operation after the target device has stopped . program.

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