JP6901612B1 - Image processing equipment and machine tools - Google Patents

Abstract

PROBLEM TO BE SOLVED: To grasp a state of a tool at an appropriate timing. An image processing apparatus is transmitted from an imaging unit of a machine tool including a holding unit 2 for holding a tool for processing a workpiece and an imaging unit 3 for imaging the tool held by the holding unit. An image processing device 10 that processes image data, the receiving unit 101 that receives the image data transmitted from the imaging unit, the image data of the tool captured by the imaging unit, and the tool data that has been converted into data in advance. A comparison unit 102 for comparison and a transmission unit 104 for transmitting the comparison result in the comparison unit are provided, and the comparison unit compares data according to an input signal after determining the state of the machining mark of the work. .. [Selection diagram] Fig. 2

Description

The present invention relates to image processing equipment and machine tools.

When machining a workpiece using a machine tool, it is necessary to understand the shape and state of the tool. Accurate machining can be realized by grasping the state of the tool. However, the current situation is that grasping the shape and state of a tool requires special work and time.

Patent Document 1 discloses a technique for managing a tool of a grinding machine by using an image. Patent Document 2 discloses a technique for capturing the tip of a tool in a photographing field of view in response to a change in a tool of a machine tool.

Japanese Unexamined Patent Publication No. 2001-269844 Japanese Unexamined Patent Publication No. 9-323240

However, it is difficult to grasp the state of the tool at an appropriate timing by any of the above patent documents.

Therefore, the apparatus and the like described in the claims are provided.

In the present disclosure, in addition to an image processing device, a machine tool or the like is provided.

These general and specific aspects may be realized by systems, methods, and computer programs, and combinations thereof.

According to the present invention, the state of the tool in the machine tool can be grasped at an appropriate timing.

It is an external view of a machine tool. It is a block diagram which shows the structure of the machine tool and the image processing apparatus which concerns on embodiment. It is a block diagram explaining the structure of the machine tool which concerns on embodiment. This is an example of tool data used in the image processing apparatus according to the embodiment. This is an example of projected image data of a tool. It is a figure which compares the work which has no processing mark, and the work which has a processing mark. This is an example of a display screen that displays the image data of the captured tool. It is a flowchart explaining the process in a machine tool. It is a flowchart explaining the processing in an image processing apparatus.

The image processing apparatus and the machine tool according to each embodiment will be described below with reference to the drawings. In the following description, the same components will be designated by the same reference numerals and description thereof will be omitted.

The "machine tool" described below uses a tool to machine a work such as metal to be machined into a desired shape by cutting, grinding, or the like.

The "image processing device" of the present embodiment is a device that processes an image captured in a machine tool. In addition, the "image processing device" detects and measures the state of the tool used for machining the work in the machine tool.

<Machine Tools>
The machine tool 1 according to the embodiment of the present disclosure has, for example, an outer shape as shown in FIG. 1, and can process a work arranged in a processing region 70. The configuration of the machine tool will be described with reference to FIGS. 1 to 3. As shown in FIG. 2, the machine tool 1 has a holding unit 2, an imaging unit 3, a numerical control unit 4, and the like. Further, the machine tool 1 may have a measuring unit 5 as shown in FIG. Further, the machine tool 1 is connected to an image processing device 10 described later.

The holding portion 2 is a portion for holding a tool for processing a work. For example, the holding portion 2 is a tool spindle 21 for attaching a tool T for machining a work, a tool post station, a magazine pot, and a tool changing arm.

As shown in FIG. 3, the tool spindle 21 can be rotated and moved by a control mechanism (not shown) while holding the tool T. The tool T is rotated or moved by a control mechanism to process a workpiece into a desired shape. The tool T includes a blade portion T1 which is a portion used for machining a work, and a shank portion T2 which is a portion held by a holder 211 of the tool spindle 21.

The machine tool 1 stores a plurality of types of tools T in the magazine 61, which is a storage unit shown in FIG. Then, the machine tool 1 can process the work by a plurality of different types of methods by holding the tool T selected from the plurality of tools T on the tool spindle 21 by using the tool change arm.

The imaging unit 3 images the tool T held by the holding unit 2. The image pickup unit 3 is, for example, a camera provided with an image pickup element such as a CCD or CMOS. The imaging unit 3 can image the tool T attached to the tool spindle 21 at a predetermined timing. For example, the imaging unit 3 images the tool T at the timing when a predetermined number of workpieces are machined using one tool T.

As shown in FIG. 3, the imaging unit 3 images the tool T attached to the tool spindle 21 from a plurality of different directions. Specifically, the tool spindle 21 rotates the tool T to be held at a predetermined pitch, and the imaging unit 3 performs imaging with the rotation of the tool T stopped. By imaging the tool T at predetermined pitch intervals in this way, the tool T can be imaged from a plurality of different directions even when the imaging unit 3 is fixed. Further, the image pickup unit 3 outputs the obtained image data to the image processing device 10. If the tool T does not fit in one image, the tool spindle 21 may move the tool T along the rotation axis.

As described above, the machine tool 1 is attached to the tool spindle 21 of the machine tool 1 by the imaging unit 3, and images of the tool T from a plurality of directions by imaging the tool T rotated at a predetermined pitch. You can get the data. For example, the imaging unit 3 captures image data each time the tool T is rotated by 18 ° with respect to the rotation axis of the tool spindle 21, so that each tool T is in the direction perpendicular to the rotation axis of the tool T. You can get multiple images from our different directions. If the rotation is 18 °, images taken from 20 directions can be acquired when the tool is rotated once. At this time, the machine tool 1 provides the image processing apparatus 10 with information on the rotation angle of the tool T together with the image data.

Further, the imaging unit 3 can also image the work held by the work holding unit 62. In the example shown in FIG. 2, the machine tool 1 includes only one imaging unit 3. In this case, the tool T and the work can be imaged by one imaging unit 3. Further, a plurality of imaging units, one for capturing the tool T and the other for imaging the work, may be provided, and the tool and the work may be imaged by separate imaging units.

As shown in FIG. 3, the illumination unit 33 is arranged so that the light emitting surface 34 faces the light receiving surface 31 of the imaging unit 3, and among the light emitted from the light emitting surface 34, the light that has passed around the tool is received. It is incident on the surface 31. Therefore, the illumination unit 33 is transmitted illumination. By using the illumination unit 33 which is a transmission illumination, it is possible to obtain a projected image in which the details of the contour of the tool T can be grasped. The configuration of the image pickup unit 3, the light receiving surface 31, the illumination unit 33, and the light emitting surface 34 shown in FIG. 3 is located at the broken line portion in FIG.

The numerical control unit 4 controls the drive control of the tool spindle 21 and the like for the tool T to perform machining.

The measuring unit 5 measures the work machined by the tool T using a measuring instrument. Specifically, when the measurement unit 5 receives a request for measurement, the measurement unit 5 measures the work. Further, the measurement unit 5 transmits the measurement result to the image processing device 10.

As the measuring unit 5 and the measuring instrument, for example, a "touch probe" that is operated so as to be in contact with the work at a predetermined position is used. At this time, the touch probe, which is the measurement unit 5, comes into contact with a plurality of points of the work, but the electric signal obtained by the contact of the plurality of points may be transmitted to the image processing apparatus as one measurement result. Alternatively, each electric signal obtained by contacting each point may be transmitted to the image processing device as a measurement result. From the information of the plurality of points obtained in this way, the image processing apparatus 10 can measure the shape of the work. The method of measuring the work is not limited to the contact measurement using the above-mentioned "touch probe", and the measurement unit 5 may be, for example, non-contact measurement using a laser displacement meter.

Further, as shown in FIG. 1, the machine tool 1 includes a work holding unit 62 and a lighting unit 63. The work holding unit 62 can hold the work to be machined, and can rotate or move the work by being driven by the drive mechanism. The illumination unit 63 can emit light when an image is taken by the image pickup unit 3. Further, the machine tool 1 includes a cover 71 that shields the machining area 70 from the outside of the machine tool 1, and the cover 71 has an opening 72 for taking out the work to be machined from the machining area 70 to the outside of the machine tool 1. A door 73 that can be opened and closed is provided. In addition, an operation panel 8 used for various operations such as machining of the machine tool 1 is provided.

<Image processing device>
An example of the image processing apparatus 10 according to the embodiment will be described with reference to FIG. The image processing device 10 processes the image data D2 transmitted from the image pickup unit 3 of the machine tool 1, and is a calculation unit 100, a storage unit 110, an input unit 120, a display unit 130, and a communication unit 140. And. The image processing device 10 is, for example, an information processing device such as a personal computer or a tablet terminal. As a so-called "tool profiler", the image processing device 10 can detect and measure the state of a tool used for machining a work in a machine tool.

The calculation unit 100 is a controller that controls the entire image processing device 10. For example, the arithmetic unit 100 reads and executes the control program P stored in the storage unit 110 to execute processing as the receiving unit 101, the comparison unit 102, the operation unit 103, the transmitting unit 104, and the indicating unit 105. .. Further, the arithmetic unit 100 is not limited to one that realizes a predetermined function by the cooperation of hardware and software, and may be a hardware circuit specially designed to realize a predetermined function. That is, the arithmetic unit 100 can be realized by various processors such as a CPU, MPU, GPU, FPGA, DSP, and ASIC.

The storage unit 110 is a recording medium for recording various information. The storage unit 110 is realized, for example, a RAM, a ROM, a flash memory, an SSD (Solid State Device), a hard disk, another storage device, or a combination thereof as appropriate. The storage unit 110 stores various data and the like used by the machine tool 1 in addition to the control program P executed by the calculation unit 100. For example, the storage unit 110 stores tool data D1, image data D2, and time data D3.

The tool data D1 is pre-converted into data with respect to a plurality of tools T used in the machine tool 1. In the example shown in FIG. 4A, the tool data D1 includes a "tool ID" that identifies the tool, a "image data" of the tool identified by the tool ID, a "tool shape", a "tool length", and the like related to the tool. Data that associates with information. The image data Im001 shown in FIG. 4B is image data associated with the tool data D1 of FIG. 4A. The "image number" shown in the tool data D1 shown in FIG. 4A is identification information of the image data of the tool. For example, the image data of the tool ID "A01" is identified by the image number "Im001" shown in FIG. 4B. It is image data. In the example shown in FIG. 4B, the format of the image data of the tool is a “projection image” in which the contour of the tool T can be grasped as described above using FIG.

The image data associated with the tool data D1 shown in FIG. 4A is not limited to the one image shown in FIG. 4B, but may be a plurality of images. For example, the tool data D1 can associate image data captured from a plurality of different directions with respect to one tool T. Further, the three-dimensional shape of the tool T can be specified from a plurality of image data captured from different directions associated with the tool data D1.

Although not shown in FIG. 4B, the image data of the tool T included in the tool data D1 may be such that the state in which the blades of the plurality of inserts are attached can be confirmed. Also in this case, the blade of each insert attached to the tool may be confirmed by the image data captured from a plurality of different directions.

The image data D2 is data of the tool T imaged by the imaging unit 3 and the work machined by the tool T.

The time data D3 is data relating to the usage time of the tool T. Specifically, the time data D3 is data relating to the cumulative time for each tool T.

The input unit 120 is an input means such as a keyboard, a mouse, and a touch panel used for inputting data and operation signals. The display unit 130 is an output means such as a display used for outputting data.

The communication unit 140 is an interface circuit (module) for enabling data communication with an external device (not shown). For example, the communication unit 140 can execute data communication with the machine tool 1.

The receiving unit 101 receives the image data D2 transmitted from the imaging unit 3 of the machine tool 1 via the communication unit 140. For example, the receiving unit 101 receives image data D2 of a plurality of projected images of the tool T, which are rotated and captured from different angles, together with information regarding the rotation angles. Further, the receiving unit 101 stores the received image data D2 of the plurality of tools T and the information regarding the rotation angle of the tool T in the storage unit 110 in association with the identification information of the tool T.

The receiving unit 101 can receive the image data D2 that captures the processed work from the imaging unit 3. The receiving unit 101 also stores the image data D2 of the work in the storage unit 110.

The comparison unit 102 compares the image data of the tool captured by the image pickup unit 3 with the data of the tool that has been converted into data in advance. Specifically, when the operation signal for comparison is input from the operation unit 103 and the comparison timing is reached, the comparison unit 102 receives the image data D2 of the tool T received by the reception unit 101 and the storage unit 110. Compare with the image data of the tool T associated with the tool data D1 stored in advance in. The comparison unit 102 can detect the state of the tool by comparing the image data D2 of the tool with the image data associated with the tool data. Therefore, the comparison unit 102 can obtain, for example, a difference in the shape of the tool used for determining whether or not maintenance of the tool is necessary. Specifically, the degree of wear of the tool T in the image data D2 is specified, and the larger the wear such that the tool wears, the smaller the tool diameter becomes. Not limited to this example, by quantifying this difference, it is possible to specify the degree of deterioration of the tool T and the presence or absence of chips wrapping around the tool T. That is, the comparison unit 102 has a function as a tool profiler.

As a comparison method in the comparison unit 102, "edge detection" can be used from the image data D2 of the tool T. An "edge" is the boundary between a bright part and a dark part that occurs in an image. Therefore, specifying this edge is to specify the shape of the tool T. Specifically, by comparing the position of the edge of the image data D2 with the position, width, region, etc. of the edge of the image data associated with the tool data D1, the degree of deterioration of the blade of the tool T or the insert of the tool T Can be identified. Further, for example, from the image data D2, it is possible to detect the wrapping of chips around the tool T as shown by the broken line portion.

As described above, when the tool data D1 includes image data captured from a plurality of directions, the comparison unit 102 uses the plurality of image data D2 captured from different directions by the receiving unit 101 for comparison. You may.

The operation unit 103 generates an operation signal for comparison at a predetermined timing and outputs the operation signal to the comparison unit 102. That is, the operation signal is a signal for determining the timing of confirmation by the tool profiler, and is a signal generated when the state of the machining mark of the work is determined. This operation signal is generated according to the machining mark of the work. For example, from the captured image of the work after processing, this operation signal is generated at a timing when the processing marks of the work such as tool marks generated on the work exceed an allowable degree. Specifically, when the processed work exceeds a predetermined allowable degree from the image data D2 of the work captured by the imaging unit 3, an operation signal is generated and output to the comparison unit 102.

FIG. 5A is a partial perspective view of the tooth surface F of the work piece on which the tool mark, which is a machining mark due to machining, is not generated. The tooth surface F shown in FIG. 5A is a smooth surface without unevenness or undulations, and is an example in which ideal processing can be performed. On the other hand, FIG. 5B is a partial perspective view of the tooth surface of the work on which the tool mark is generated. As shown in the example shown in FIG. 5B, processing may generate a minute vortex G on the surface of the work, which is not the original purpose of processing. In some cases, this vortex G has no problem as a work. However, when the tool T is deteriorated, unevenness and undulations become large, and a tool mark of a vortex G to an unfavorable degree may be generated. In such a case, since it is necessary to confirm the state of the tool T, the operation unit 103 generates an operation signal. That is, in the image processing device 10, the timing of checking the state of the tool T with the tool profiler can be adjusted according to the machining marks of the work such as the tool mark. For example, by adjusting the timing of generating this operation signal, it is possible to shorten or lengthen the interval of the timing of checking the state of the tool T by the tool profiler in the image processing device 10.

Further, the operation unit 103 may generate an operation signal even when the processing mark of the additional processing generated on the work exceeds an allowable degree. This is because if the unevenness or undulations that are the machining marks generated by the additional machining are large, the tool T is worn or damaged.

The operation unit 103 may generate an operation signal not only at the timing determined by using the image data D2 but also at the timing operated by the operator via the input unit 120 or the like. As a result, for example, when the operator visually finds a machining mark on the work, the operation unit 103 can generate an operation signal by operating the work through the input unit.

The transmission unit 104 transmits the comparison result of the comparison unit 102 to an external device via the communication unit 140. For example, the transmission unit 104 transmits the comparison result to the operation panel 8. Alternatively, the transmission unit 104 may transmit the numerical value obtained as the comparison result to the terminal of the operator and notify the operator of the state of the tool T. Here, if the state of the tool T is a comparison result that can be determined that maintenance is not necessary at present, the transmission unit 104 may not transmit the comparison result. That is, only the comparison result for which maintenance of the tool T is determined to be necessary may be transmitted to an external device.

The instruction unit 105 transmits a request for imaging the tool T to the machine tool 1 via the communication unit 140 at a predetermined timing. This timing may be determined by the cumulative time of use of the tool T. For example, the instruction unit 105 stores the cumulative time used for machining in the storage unit 110 for each tool T. The cumulative time of this use may be included in the tool data D1, or as shown in FIG. 2, the time data D3 may be stored in the storage unit 110 separately from the tool data D1. Then, when the cumulative time of use stored as the time data D3 exceeds the time set as a threshold value in advance, the instruction unit 105 transmits a request for imaging the tool T to the machine tool 1. Here, the predetermined time used as the threshold value can be predetermined for each type of the tool T according to the degree of deterioration of the tool T and the like, and can be included in the tool data D1. For example, for the tool T that easily deteriorates, it is preferable to set a shorter time as a predetermined time than the tool T that does not easily deteriorate. As a result, the image pickup unit 3 can take an image of the image data D2 at a timing at which there is a high possibility that the tool T has deteriorated.

For example, the image data D2 captured by the image pickup unit 3 may be confirmed on a display screen as shown in FIG. 6A. In the display screen W of the example shown in FIG. 6A, the display unit B1 includes the image data D2 of the tool T. As shown in FIG. 6A, the display screen W includes an automatically recognized cutting edge contact line L1 indicating the cutting edge of the tool T automatically recognized by the image processing device 10. Further, the display screen W includes a correction cutting edge contact line L2 for correcting the automatic recognition cutting edge contact line L1. For example, when the display screen W has a touch panel function capable of inputting operations by contact, as shown in FIG. 6A, the user touches the correction cutting edge contact line L2 and slides to the actual cutting edge of the tool T. To do. As a result, as shown in FIG. 6B, the correction cutting edge contact line L2 is moved to the actual cutting edge of the tool T. On the display screen W shown in FIG. 6B, it can be seen that the automatic recognition cutting edge contact line L1 and the correction cutting edge contact line L2 have a deviation of 40.8 μm. Thereby, the deviation of the position of the cutting edge of the tool T can be corrected. Then, the position of the cutting edge of the tool T corrected in this way can be used to correct the position of the tool T and prevent defects due to machining. The display units B2 to B4 display the image data of the tool T acquired at a timing different from the image data displayed on the display unit B1.

As described above, in the image processing apparatus 10 according to the embodiment, the tool profiler is made to function at the timing when the operation signal is generated by the operation unit 103 according to the state of the work machined by the tool T, and the tool maintenance is determined. It can be used. For example, it is possible to determine whether or not the tool T needs to be replaced by using the state of the work obtained by the image processing device 10. It is preferable that the tool T can be used for machining for as long as possible without replacement or maintenance if the work condition is not a problem, rather than frequent replacement or maintenance. On the other hand, when there is a problem in the machining state of the work, it is preferable to replace or maintain the tool T as soon as possible. Therefore, the image processing device 10 can confirm the state of the tool T when the processing state of the work is worse than expected by the image data D2 received from the image pickup unit 3. As a result, the image processing apparatus 10 can grasp the state of the tool in the machine tool at an appropriate timing.

<Processing in machine tools>
The processing related to the acquisition of image data in the machine tool 1 will be described with reference to the flowchart shown in FIG. In the machine tool 1, for example, at the timing when the machining of the workpiece is completed (YES in S01), the imaging unit 3 images the workpiece machined by the tool T (S02).

Next, the image capturing unit 3 transmits the image data of the work captured in step S02 to the image processing device 10 (S03).

Further, when the tool imaging instruction requesting the image data of the tool T is received from the image processing device 10 (YES in S04), the imaging unit 3 acquires the image data of the tool T (S05).

Subsequently, the image capturing unit 3 transmits the image data of the tool T captured in step S05 to the image processing device 10 (S06).

For example, in the machine tool 1, as long as the machining of a new workpiece is continued (YES in S07), the processes of steps S01 to S06 are repeated.

The order of processing shown in FIG. 7 is an example, and is not limited to the example shown in FIG. 7 as long as the image data of the work and the image data of the tool can be transmitted to the image processing device 10. For example, steps S01 to S03 are a series of processes related to image capture of the work, and steps S04 to S06 are a series of processes related to image data acquisition of the tool T. If necessary, image data of the tool T is imaged. After that, an image of the work may be taken.

<Processing in the image processing device>
The process of confirming the tool T and measuring the work in the image processing apparatus 10 will be described with reference to the flowchart shown in FIG.

The receiving unit 101 receives the image data D2 of the work imaged by the imaging unit 3 and stores it in the storage unit 110 (S21).

The instruction unit 105 transmits an image pickup instruction requesting image capture of the image data D2 of the tool T to the image pickup unit 3 at a predetermined timing (YES in S22) (S23). This predetermined timing is, for example, a timing when the cumulative time of use of the tool T exceeds a predetermined time.

The receiving unit 101 receives the image data D2 of the tool T imaged by the imaging unit 3 and stores it in the storage unit 110 (S24).

When the operation signal is generated by the operation unit 103 (YES in S25), the comparison unit 102 associates the image data of the tool T received in step S24 with the image data stored in the storage unit 110 by the tool data D1. Compare with (S26).

The transmission unit 104 transmits the comparison result in step S26 to an external device (S27). For example, the operation panel and the comparison unit 102 may output the comparison result to the operation panel 8 or another output device.

While the machining of the work continues in the machine tool 1 (YES in S28), the processing of steps S21 to S27 is repeated in the image processing apparatus 10.

The order of processing shown in FIG. 8 is an example, and if the image data of the work and the image data of the tool T can be received and the state of the tool T can be confirmed from the state of the work, it is limited to the example shown in FIG. I can't. For example, step S21 is a process related to the acquisition of an image of the work, and steps S22 to S24 are a series of processes related to the confirmation of the state of the tool T. If necessary, the image of the work is imaged after the image data of the tool T is acquired. May be obtained.

As described above, the above-described embodiment has been described as an example of the technology disclosed in the present application. However, the technique in the present disclosure is not limited to this, and can be applied to embodiments in which changes, replacements, additions, omissions, etc. are made as appropriate.

By using the technique disclosed in this application, it is possible to grasp the state of the tool in the machine tool and improve the machining accuracy.

The image processing apparatus, machine tool and image processing method described in all the claims of the present disclosure are realized by cooperation with hardware resources such as a processor, a memory, and a program.

The image processing apparatus, machine tool and image processing method of the present disclosure are useful for grasping the state of tools of a machine tool, for example.

1 Machine tool 2 Holding unit 3 Imaging unit 4 Numerical control unit 5 Measuring unit 10 Image processing device 101 Reception unit 102 Comparison unit 103 Operation unit 104 Transmission unit 105 Indicator unit

Claims (4)

It is transmitted from the imaging unit of the machine tool including a tool spindle for holding a tool for machining a work while rotating the tool and an imaging unit for capturing a projected image of the tool held on the tool spindle. An image processing device that processes image data
A receiving unit that receives the projected image data transmitted from the imaging unit, and a receiving unit.
The edge of the projected image is specified from the projected image data of the tool captured by the imaging unit, the edge of the projected image is specified from the projected image data of the tool captured by the imaging unit on the surface of the work, and the edge of the projected image is specified. A comparison unit that compares the data of the tool, which has been digitized in advance, according to the input signal after determining that there is a machining mark on the surface, which is a tool mark created by cutting the tool.
A transmission unit that transmits the comparison result in the comparison unit and
The automatic recognition cutting edge contact line calculated from the specified edge of the projected image data of the tool and the captured image of the cutting edge of the tool held on the tool spindle are displayed and controlled on the display unit, and the correction cutting edge contact line is displayed. A display control unit that controls the display to move on the unit and controls the display of the distance between the automatic recognition cutting edge contact line and the correction cutting edge contact line.
An image processing device comprising. The image processing according to claim 1, further comprising a storage unit for storing the usage time of the tool and an instruction unit for instructing the imaging unit to image the tool when the usage time exceeds a predetermined time. apparatus. The image processing apparatus according to claim 1 or 2 , wherein the comparison unit identifies the edge of the projected image from the projected image data of one tool captured from a plurality of different directions, and specifies the three-dimensional shape of the tool. .. The image processing apparatus according to any one of claims 1 to 3.
A machine tool equipped with a control device for controlling the machining of a workpiece.

Images