JP6987174B2 - Grinding equipment, manufacturing method of workpieces, and grinding system - Google Patents

Description

The present invention relates to a machine tool, a method for manufacturing a workpiece, and a machining system.

For example, a grinding device is known as a machine tool for processing a work (see Patent Document 1).

Japanese Unexamined Patent Publication No. 2016-016483

Machined products manufactured by machine tools are inspected for processing quality by an inspection device in a subsequent process. It is difficult to inspect all of the manufactured workpieces because the inspection takes time. Therefore, a sampling inspection is carried out in which a part of the manufactured workpieces is selected and inspected. In the sampling inspection, there is a possibility that a work piece with poor processing quality will be shipped. Further, in the inspection using an inspection device, a workpiece having poor processing quality is found in a post-process, and it is difficult to detect it in real time during machining.

It is an object of the present invention to provide a machine tool, a method for manufacturing a workpiece, and a machining system capable of inspecting the machining quality in real time during machining and suppressing the production of a workpiece having a poor machining quality.

According to the first aspect of the present invention, the tool for processing the work in contact with the work, the state amount data acquisition unit in which the state amount data of the work and the tool are input, and the dynamic characteristics of the tool. The state quantity estimation data calculation unit that calculates the state quantity estimation data from the simulation model including the device dynamic characteristic model shown and the work model showing the target shape of the work, and the state quantity estimation data and the state quantity estimation data are used as the basis for the state quantity estimation data. A machine tool including a machining state calculation unit for calculating machining state data indicating a machining state of a work is provided.

According to the second aspect of the present invention, the work and the tool are brought into contact with each other to machine the work with the tool, the state quantity data of the work and the tool is acquired in the machining, and the tool is used. The state quantity estimation data is calculated from a simulation model including a device dynamic characteristic model showing the dynamic characteristics of the work and a work model showing the target shape of the work, and the work is based on the state quantity data and the state quantity estimation data. It includes calculating the machining state data indicating the machining state of the above, outputting the machining state data in the machining, and controlling the machining conditions by the tool based on the machining state data in the machining. A method for manufacturing a work piece is provided.

According to the third aspect of the present invention, the tool for processing the work in contact with the work, the state amount data acquisition unit in which the state amount data of the work and the tool are input, and the dynamic characteristics of the tool. The state quantity estimation data calculation unit that calculates the state quantity estimation data from the simulation model including the device dynamic characteristic model shown and the work model showing the target shape of the work, and the state quantity estimation data and the state quantity estimation data are used as the basis for the state quantity estimation data. A machining system including a machining state calculation unit for calculating machining state data indicating a machining state of a work is provided.

According to the aspect of the present invention, there is provided a machine tool, a method for manufacturing a workpiece, and a machining system capable of inspecting the machining quality in real time during machining and suppressing the production of a workpiece having a poor machining quality.

FIG. 1 is a plan view schematically showing an example of a machine tool according to the present embodiment. FIG. 2 is a side view schematically showing an example of a machine tool according to the present embodiment. FIG. 3 is a functional block diagram showing an example of the control device according to the present embodiment. FIG. 4 is a schematic diagram for explaining the behavior of the work according to the present embodiment. FIG. 5 is a diagram schematically showing the relationship between the work and the tool according to the present embodiment. FIG. 6 is a flowchart showing an example of a method for manufacturing a workpiece according to the present embodiment. FIG. 7 is a diagram showing an example of machining state data calculated by the machine tool according to the present embodiment. FIG. 8 is a diagram schematically showing an example of a processing system according to the present embodiment.

Hereinafter, embodiments according to the present invention will be described with reference to the drawings, but the present invention is not limited thereto. The components of the embodiments described below can be combined as appropriate. In addition, some components may not be used.

In the following description, a three-dimensional Cartesian coordinate system will be set, and the positional relationship of each part will be described with reference to the three-dimensional Cartesian coordinate system. The direction parallel to the X-axis in the predetermined plane is the X-axis direction, the direction parallel to the Y-axis orthogonal to the X-axis in the predetermined plane is the Y-axis direction, and the X-axis and the Z-axis orthogonal to the Y-axis are parallel. The direction is the Z-axis direction. Further, the rotation or tilt direction centered on the X axis is defined as the θX direction, the rotation or tilt direction centered on the Y axis is defined as the θY direction, and the rotation or tilt direction centered on the Z axis is defined as the θZ direction. The predetermined plane is an XY plane, which is parallel to the horizontal plane in this embodiment. The Z-axis direction is the vertical direction.

[Machine Tools]
FIG. 1 is a plan view schematically showing an example of a machine tool 100 according to the present embodiment. FIG. 2 is a side view schematically showing an example of the machine tool 100 according to the present embodiment. In this embodiment, the machine tool 100 is a grinding device.

As shown in FIGS. 1 and 2, the machine tool 100 includes a tool 1 for processing the work W in contact with the work W, a first rotating device 10 for rotating the tool 1, and a second rotation for rotating the work W. It includes a device 20, a drive device 30 for moving the tool 1 in the X-axis direction, a drive device 40 for moving the tool 1 in the Y-axis direction, and a control device 50.

The work W is a machining object to be machined by the machine tool 100. The work W is a columnar member. The machine tool 100 processes the work W to manufacture a camshaft or a crankshaft.

The tool 1 is a grindstone for grinding. The tool 1 grinds the work W by rotating the work W in contact with the work W.

The first rotating device 10 rotates the tool 1 around a rotating axis AX parallel to the Y axis. The first rotating device 10 includes a support mechanism 11 that rotatably supports the tool 1 and a first motor 12 that generates power to rotate the tool 1. The support mechanism 11 and the first motor 12 are supported by a stage member 13 that can move in the X-axis direction.

The second rotating device 20 rotates the work W about a rotation axis BX parallel to the Y axis. The second rotating device 20 has a support mechanism 21 that rotatably supports one end of the work W, a support mechanism 22 that rotatably supports the other end of the work W, and a power for rotating the work W. It has a second motor 23 to generate. The support mechanism 21 and the support mechanism 22 are supported by the base member 2.

The drive device 30 moves the tool 1 in the X-axis direction orthogonal to the rotation axis AX of the tool 1. The X-axis direction is the feed direction of the tool 1. The drive device 30 moves the tool 1 in the X-axis direction by moving the stage member 13 in the X-axis direction. The drive device 30 has a third motor 31 that generates power to move the tool 1 in the X-axis direction. The third motor 31 includes a linear motor. The third motor 31 is a linear motor. The third motor 31 may include a rotary motor, and the tool 1 may be moved in the X-axis direction by a ball screw mechanism operated by the third motor 31. When the stage member 13 moves in the −X direction, the tool 1 moves in the −X direction and is pressed against the work W.

The drive device 40 moves the tool 1 in the Y-axis direction. The drive device 40 moves the tool 1 in the Y-axis direction by moving the stage member 13 in the Y-axis direction. The drive device 40 has a fourth motor 41 that generates power to move the tool 1 in the Y-axis direction. The fourth motor 41 includes a linear motor. The fourth motor 41 is a linear motor. The fourth motor 41 may include a rotary motor, and the tool 1 may be moved in the Y-axis direction by a ball screw mechanism operated by the fourth motor 41. The stage member 13 is supported by the base member 2 via the drive device 30 and the drive device 40.

The control device 50 includes a computer system. The control device 50 includes a processor such as a CPU (Central Processing Unit), a storage device including a non-volatile memory such as ROM (Read Only Memory) and a volatile memory such as RAM (Random Access Memory), and input / output. It has an interface device.

[Control system]
Next, an example of the control system 200 of the machine tool 100 according to the present embodiment will be described. FIG. 3 is a functional block diagram showing an example of the control system 200 according to the present embodiment.

As shown in FIG. 3, the control system 200 includes a control device 50, a first motor 12 that generates power for rotating the tool 1 around the rotation axis AX, and a rotation speed sensor 14 that detects the rotation speed of the tool 1. A third motor 31 that generates power to move the tool 1 in the X-axis direction, a position sensor 32 that detects the position of the tool 1 in the X-axis direction, and a power to rotate the work W around the rotation axis BX. A second motor 23 to be generated, a rotation angle sensor 24 for detecting the rotation angle of the work W, and a CAD data holding unit 60 for holding CAD (Computer Aided Design) data which is design data of the work W are provided.

The control device 50 includes a state quantity data acquisition unit 51 into which state quantity data of the work W and the tool 1 are input, a device dynamic characteristic model showing the dynamic characteristics of the tool 1, and a work model showing the target shape of the work W. The state quantity estimation data calculation unit 52 that calculates the state quantity estimation data from the model, and the machining state calculation unit 53 that calculates the machining status data indicating the machining status of the work W based on the state quantity data and the state quantity estimation data. To prepare for.

Further, the control device 50 controls the machining conditions by the tool 1 based on the output unit 54 that outputs the machining state data calculated by the machining state calculation unit 53 and the machining state data calculated by the machining state calculation unit 53. It includes a machining control unit 55 and a storage unit 56.

The simulation model is preset based on a function, a map, or the like, and is stored in the storage unit 56.

The state quantity means an quantity uniquely determined by the state of the tool 1 or the work W in contact with the tool 1. In the present embodiment, the state amount data is detected by the output data d1 of the first motor 12, the rotation speed data d2 of the tool 1 detected by the rotation speed sensor 14, the output data d3 of the third motor 31, and the position sensor 32. The position data d4 of the tool 1 in the X-axis direction, the output data d5 of the second motor 23, and the rotation angle data d6 of the work W detected by the rotation angle sensor 24 are included.

The output data d1 of the first motor 12 includes the torque of the first motor 12. The output data d1 is derived based on the current value output from the first motor 12. The output data d1 is output to the state quantity data acquisition unit 51.

The rotation speed sensor 14 includes, for example, a rotary encoder, and detects rotation speed data d2 indicating the rotation speed of the tool 1. The rotation speed data d2 is output to the state quantity data acquisition unit 51.

The output data d3 of the third motor 31 includes the thrust of the third motor 31. The output data d3 is derived based on the current value output from the third motor 31. The output data d3 is output to the state quantity data acquisition unit 51.

The position sensor 32 includes, for example, a linear encoder, and detects position data d4 indicating the position of the tool 1 in the X-axis direction. In the present embodiment, the position sensor 32 detects the position data d4 of the tool 1 by detecting the movement amount of the third motor 31. The position data d4 is output to the state quantity data acquisition unit 51.

The output data d5 of the second motor 23 includes the torque of the second motor 23. The output data d5 is derived based on the current value output from the second motor 23. The output data d5 is output to the state quantity data acquisition unit 51.

The rotation angle data 24 includes, for example, a rotary encoder, and detects rotation angle data d6 indicating the rotation angle of the work W. The rotation angle data d6 is output to the state quantity data acquisition unit 51.

The CAD data holding unit 60 holds the CAD data d7. The CAD data d7 includes the target shape data of the work W and the physical property data of the work W. The target shape data of the work W includes the cross-sectional shape data of the work W orthogonal to the rotation axis BX.

The state amount data acquisition unit 51 acquires output data d1, rotation speed data d2, output data d3, position data d4, output data d5, and rotation angle data d6 as state amount data. The state quantity data is not limited to the output data d1, the rotation speed data d2, the output data d3, the position data d4, the output data d5, and the rotation angle data d6. The state quantity data may include, for example, the coolant flow rate.

The state quantity estimation data calculation unit 52 calculates the machining resistance fluctuation as the state quantity estimation data from the device dynamic characteristic model showing the dynamic characteristics of the tool 1. Further, the state quantity estimation data calculation unit 52 calculates the contact angle variation or contact position variation between the tool 1 and the work W as the state quantity estimation data from the work model showing the target shape of the work W based on the CAD data d7.

The device dynamic characteristic model is calculated by modeling the tool 1 and identifying the system. Modeling is the process of building a mathematical model that characterizes the behavior of an object. Modeling transforms the object into a simplified mathematical representation. For the tool 1, for example, a device dynamic characteristic model having a mass component, a damper component, and a spring component is calculated.

System identification is the process of experimentally verifying the correctness of the modeling performed earlier. In system identification, for example, a process of experimentally inputting input signals of various frequencies to the tool 1 and measuring the amplitude or phase output from the tool 1 is performed. Further, in system identification, when input signals of various frequencies are input to the tool 1, a process of measuring the speed of the tool 1 is performed. System identification experimentally verifies the correctness of modeling.

Based on the result of system identification, dynamic characteristic data showing the dynamic characteristics of the tool 1 is derived. The dynamic characteristic data of the tool 1 includes the mass component, the damper component, and the spring component of the tool 1. Further, the dynamic characteristic data of the tool 1 includes known data relating to the tool 1 such as the outer shape and dimensions of the tool 1.

The work model is calculated based on the CAD data. The work model includes target shape data of the work W in machining. The target shape data of the work W includes the cross-sectional shape data of the work W orthogonal to the rotation axis BX. Further, the work model includes physical property data of the work W such as the elastic modulus of the work W. Further, the work model includes the dynamic characteristic data of the work W. The dynamic characteristic data of the work W includes, for example, a mass component, a damper component, and a spring component of the work W. By calculating the work model, for example, the variation in the amount of deflection of the work W when an external force is applied is calculated.

Further, the state quantity estimation data calculation unit 52 includes a plurality of Kalman filters 52C, and can extract a plurality of state quantity data from one set of input / output data. The state quantity estimation data calculation unit 52, for example, based on the output data d1 from the first motor 12 and the rotation speed data d2 from the rotation speed sensor 14, uses the grinding resistance of the tool 1 and the machining of the work W as the state quantity estimation data. The starting point, the amount of wear of the tool 1, and the like can be extracted.

The machining state calculation unit 53 processes the work W based on the state quantity data acquired by the state quantity data acquisition unit 51 and the state quantity estimation data calculated by the state quantity estimation data calculation unit 52 using the simulation model. The machining state data indicating the state is calculated. The state quantity data supplied to the processing state calculation unit 53 includes the state quantity estimation data extracted by the Kalman filter 52C of the state quantity estimation data calculation unit 52. The state amount data supplied to the machining state calculation unit 53 includes output data d1 supplied from the first motor 12, rotation speed data d2 supplied from the rotation speed sensor 14, and output supplied from the third motor 31. It includes data d3, position data d4 supplied from the position sensor 32, output data d5 supplied from the second motor 23, and rotation angle data d6 supplied from the rotation angle sensor 24.

The state quantity estimation data calculation unit 52 calculates the machining resistance of the tool 1 based on the output data d1 of the first motor 12, the rotation speed data d2 of the tool 1, and the simulation model. In the present embodiment, the machining resistance of the tool 1 is the grinding resistance of the tool 1. When the output data d1 is input to the simulation model, the rotation speed data of the tool 1 in the idling state in which the tool 1 and the work W are not in contact with each other is calculated. The state quantity estimation data calculation unit 52 is based on the difference between the rotation speed data of the tool 1 in the idling state calculated based on the output data d1 and the simulation model and the rotation speed data d2 detected by the rotation speed sensor 14. , The machining resistance of the tool 1 can be calculated.

The machining resistance of the tool 1 may be the grinding resistance extracted by the Kalman filter 52C of the state quantity estimation data calculation unit 52.

Further, the machining state calculation unit 53 can calculate the deflection amount fluctuation data indicating the deflection amount of the work W based on the machining resistance and the work model. The machining resistance is equivalent to the load acting on the work W. In the present embodiment, the load acting on the work W is the grinding force acting on the work W. As described above, the work model includes the cross-sectional shape data of the work W and the physical property data of the work W. The machining state calculation unit 53 can calculate the deflection amount fluctuation data of the work W based on the load acting on the work model and the work model.

Further, the machining state calculation unit 53 calculates the shape error variation of the work W based on the control command data output to the third motor 31 and the calculated deflection amount variation data of the work W.

FIG. 4 is a schematic diagram showing the relationship between the control command data output to the third motor 31 according to the present embodiment and the amount of deflection of the work W. The command cut amount for the work W is calculated based on the control command data. The command cut amount indicating the target cut amount of the work W includes the target operating amount of the third motor 31. When the work W bends according to the grinding force acting on the work W, the work W escapes from the tool 1. As a result, the actual cutting amount indicating the actual cutting amount of the work W is smaller than the commanded cutting amount by the amount corresponding to the bending amount. That is, when the work W is bent by the cutting force acting on the work W, the work W is machined only by an amount smaller than the command cut amount, and a shape error occurs in the work W with respect to the target shape. When the grinding force acting on the work W fluctuates depending on the target shape of the work W, machining conditions, etc., the amount of deflection of the work W, that is, the shape error of the work W with respect to the target shape fluctuates.

Therefore, the machining state calculation unit 53 determines the shape of the work W with respect to the target shape defined by the CAD data based on the control command data output to the third motor 31 and the calculated deflection amount fluctuation data of the work W. The error fluctuation can be calculated.

Further, the state quantity estimation data calculation unit 52 calculates the contact position C between the work W and the tool 1 based on the rotation angle data d6 and the work model. The contact position C indicates a machining point at which the work W is machined by the tool 1.

FIG. 5 is a schematic diagram showing the relationship between the work W and the tool 1 according to the present embodiment. The tool 1 rotates about the rotation axis AX, and the work W rotates about the rotation axis BX. The work W is machined into a camshaft or crankshaft. The work W is non-circular in the cross section orthogonal to the rotation axis BX. In a cross section orthogonal to the axis of rotation AX, the tool 1 is substantially circular.

When the rotating non-circular work W and the rotating circular tool 1 come into contact with each other, the distance between the contact position C of the work W in contact with the tool 1 and the rotation shaft BX changes as the work W rotates.

As described above, the work model includes cross-sectional shape data of the work W orthogonal to the rotation axis BX. Therefore, if the rotation angle of the work W in the rotation direction about the rotation axis BX is known, the contact position C of the work W in contact with the tool 1 is derived. The state quantity estimation data calculation unit 52 can calculate the contact position C between the work W and the tool 1 based on the rotation angle data d6 and the work model.

Further, the machining state calculation unit 53 calculates the unevenness of the surface of the work W based on the output data d3 of the third motor 31 and the position data d4 of the tool 1 in the X-axis direction.

There is a possibility that the rotation axis AX of the tool 1 fluctuates and the tool 1 swings around. When the tool 1 swings around, chatter vibration occurs in the tool 1, and at least one of the tool 1 and the work W vibrates slightly in the X-axis direction. When chatter vibration occurs, fine irregularities are formed on the surface of the work W.

When chatter vibration occurs, the output data d3 of the third motor 31 that moves the tool 1 in the X-axis direction fluctuates. Therefore, the machining state calculation unit 53 can calculate the chatter force [N] indicating the presence or absence of chatter vibration and the chatter vibration force as the machining state data based on the output data d3 of the third motor 31. can. Further, the machining state calculation unit 53 calculates the chatter amount [μm] indicating the amplitude of the chatter vibration as the machining state data based on the position data d4 of the tool 1 in the X-axis direction detected by the position sensor 32. Can be done.

In the present embodiment, the output data d3 in the frequency band corresponding to the rotation speed of the tool 1 is extracted from the output data d3 acquired by the state quantity data acquisition unit 51 by the filtering process. The processing state calculation unit 53 calculates the chattering force based on the extracted output data d3. Similarly, the position data d4 in the frequency band corresponding to the rotation speed of the tool 1 is extracted from the position data d4 acquired by the state quantity data acquisition unit 51 by the filtering process. The processing state calculation unit 53 calculates the chattering amount based on the extracted position data d4. The frequency band corresponding to the rotation speed of the tool 1 is calculated from the rotation speed data d2 of the tool 1.

The output unit 54 outputs the processing state data calculated by the processing state calculation unit 53. The output unit 54 outputs the machining state data in the machining by the tool 1. That is, the output unit 54 outputs the machining state data of the work W in real time while the work W is being machined.

The machining control unit 55 controls the machining conditions by the tool 1 based on the machining state data calculated by the machining state calculation unit 53. In the present embodiment, the machining control unit 55 feedback-controls at least one of the first motor 12, the third motor 31, and the second motor 23 based on the machining state data calculated by the machining state calculation unit 53. ..

[Manufacturing method of processed products]
Next, a method for manufacturing a processed product according to the present embodiment will be described. FIG. 6 is a flowchart showing an example of a method for manufacturing a workpiece according to the present embodiment. In the present embodiment, the machine tool 100 is used to manufacture a camshaft or a crankshaft, which is a workpiece, from the work W.

The work W is supported by the support mechanism 21 and the support mechanism 22. The first rotating device 10 rotates the tool 1 around the rotating shaft AX, and the second rotating device 20 causes the work W to rotate around the rotating shaft BX. With the tool 1 rotating and the work W rotating, the tool 1 is moved in the −X direction by the drive device 30 so that the tool 1 and the work W come into contact with each other.

In a state where the work W and the tool 1 are in contact with each other and the work W is machined by the tool 1, the state amount data acquisition unit 51 is the output data d1 of the first motor 12 and the tool 1 detected by the rotation speed sensor 14. Rotation speed data d2, output data d3 of the third motor 31, position data d4 of the tool 1 in the X-axis direction detected by the position sensor 32, output data d5 of the second motor 23, and rotation angle sensor 24. The state quantity data including the rotation angle data d6 of the work W is acquired (step S10).

The state quantity estimation data calculation unit 52 calculates the state quantity estimation data from a simulation model including a device dynamic characteristic model showing the dynamic characteristics of the tool 1 and a work model showing the target shape of the work W (step S20).

The machining state calculation unit 53 indicates a machining state of the work W based on the state quantity data acquired by the state quantity data acquisition unit 51 and the state quantity estimation data calculated by the state quantity estimation data calculation unit 52. Data is calculated (step S30).

In the present embodiment, the state quantity estimation data calculation unit 52 calculates the machining resistance of the tool 1 based on the output data d1 of the first motor 12, the rotation speed data d2 of the tool 1, and the simulation model. The Kalman filter 52C of the state quantity estimation data calculation unit 52 may extract the machining resistance of the tool 1 from the output data d1 of the first motor 12.

After the machining resistance of the tool 1 is derived, the machining state calculation unit 53 calculates the bending amount fluctuation data of the work W based on the machining resistance and the work model. The machining resistance is equivalent to the load acting on the work W. Further, the work model includes the target shape data of the work W, the physical property data of the work W, and the dynamic characteristic data of the work W. The machining state calculation unit 53 can calculate the deflection amount fluctuation data indicating the deflection amount variation of the work W based on the load acting on the work W and the work model.

By calculating the deflection amount fluctuation data of the work W, the actual cut amount with respect to the command cut amount is calculated as described with reference to FIG. By calculating the actual cut amount, the shape error variation of the work W with respect to the target shape defined by the CAD data is calculated. The machining state calculation unit 53 can calculate error data indicating the shape error variation of the work W with respect to the target shape as the machining state data.

Further, as described with reference to FIG. 5, the state quantity estimation data calculation unit 52 includes the work W and the tool 1 based on the rotation angle data d6 of the work W, the position data d4 of the tool 1, and the work model. The contact position C can be calculated. The contact position C indicates a machining point where the work W comes into contact with the tool 1. By calculating the contact position C, the machining state calculation unit 53 can grasp which part of the work W is machined and how much. In other words, the machining state calculation unit 53 can calculate the shape error variation with respect to the target shape for each of the plurality of portions of the work W in the rotation direction about the rotation axis BX.

Further, the machining state calculation unit 53 calculates the depth and pitch of the unevenness on the surface of the work W generated due to the chatter vibration based on the output data d3 of the third motor 31 and the position data d4 of the tool 1. can do.

That is, in the present embodiment, the machining state calculation unit 53 uses a plurality of work Ws in the rotation direction with respect to the target shape as machining state data of the work W based on the state quantity data acquired during machining of the work W. It is possible to calculate the error data for each of the parts and the unevenness data on the surface of the work W caused by the chattering vibration.

Further, the machining state calculation unit 53 can calculate and estimate the wear amount of the tool 1 based on the machining resistance of the tool 1 which is the state quantity estimation data and the number of workpieces W machined by the tool 1. .. For example, after the estimated machining resistance (grinding resistance) of the tool 1 has settled, the work W is rotated twice to roughly grind each of the plurality of workpieces W, and each of the plurality of workpieces W is roughly ground. The amount of wear of the tool 1 at that time is acquired. The machining state calculation unit 53 calculates a representative wear amount indicating an average value of the wear amount of the tool 1 when each of the plurality of workpieces W is roughly ground. The representative wear amount is stored in the storage unit 59. The machining state calculation unit 53 can estimate the wear amount of the tool 1 based on the calculated representative wear amount of the tool 1 and the number of workpieces W machined using the tool 1.

During machining by the tool 1, the output unit 54 outputs the machining state data calculated by the machining state calculation unit 53 (step S40). The output unit 54 outputs machining state data in real time during machining of the work W. The output unit 54 outputs processing state data to a display device in real time, for example.

FIG. 7 is a diagram showing an example of machining state data calculated by the machine tool 100 according to the present embodiment. The graph shown in FIG. 7 is displayed on the display device.

In the graph shown in FIG. 7, the horizontal axis indicates the angle of the portion of the work W in the rotation direction when the reference portion of the work W is set to 0 [°]. The vertical axis shows the error data of each part of the work W with respect to the target shape.

In FIG. 7, the line La shows the processing state data output from the output unit 54. By acquiring the state quantity data in the machine tool 100, the machining state calculation unit 53 can calculate the machining state data of the work W in real time while the work W is being machined. The output unit 54 can output the machining state data of the work W in real time while the work W is being machined.

The line Lb shows the error data of the work W detected by the inspection device in the post-process after machining by the machine tool 100. It can be seen that the line La and the line Lb are sufficiently matched.

The machining control unit 55 controls the machining conditions by the tool 1 based on the machining state data calculated by the machining state calculation unit 53 in the machining of the work W using the tool 1 (step S50). The machining control unit 55 has the first motor 12, the third motor 31, and the second motor so that the calculated error becomes 0 [μm] based on the machining state data calculated by the machining state calculation unit 53. Feedback control is performed on at least one of the 23.

[Action and effect]
As described above, according to the present embodiment, the machining state data of the work W is calculated in real time based on the state quantity data acquired during the machining of the work W. The machining state data of the work W includes error data indicating the shape error variation of the work W with respect to the target shape, and indicates the machining quality of the work W. According to this embodiment, by using the simulation model, the processing quality of the work W, which cannot be directly measured during the processing of the work W, is virtually calculated by arithmetic processing based on the state quantity data and the simulation model. Can be inspected.

Therefore, it is not necessary to inspect the work piece by using an inspection device in a post-process as in the prior art. Since a large and expensive inspection device is not required, the equipment cost can be suppressed.

Further, the processing quality of the work W is inspected in real time based on the state quantity data acquired during the processing of the work W. Therefore, it is not necessary to separately set an inspection time for inspection of processing quality. Therefore, it is possible to inspect the processing quality of all the manufactured products at low cost. Therefore, the shipment of processed products with poor processing quality is suppressed.

Further, according to the present embodiment, an output unit 54 for outputting machining state data is provided in machining the work W by the tool 1. As a result, the machining state data calculated by the machining state calculation unit 53 is output in real time during the machining of the work W. For example, by outputting the machining state data to the display device in real time, the manager can visually check the machining quality of the work W in real time via the display device.

Further, according to the present embodiment, a machining control unit 55 for controlling the machining conditions of the work W by the tool 1 based on the machining state data is provided. The machining control unit 55 can feedback control the machine tool 100 so that the shape error of the work W is suppressed based on the machining state data calculated in real time by the machining state calculation unit 53. Therefore, the machining conditions of the work W are optimized in a short time, and a workpiece with good machining quality can be efficiently manufactured in a short time.

Further, in the present embodiment, the output data d1 of the first motor 12 that generates the power to rotate the tool 1 is acquired as the state quantity data. By processing the output data d1 of the first motor 12 in the Kalman filter 52C, it is possible to acquire various state quantity data such as the grinding resistance of the tool 1, the machining start point of the work W, and the wear amount of the tool 1. can.

Further, in the present embodiment, the rotation speed data d2 of the tool 1 detected by the rotation speed sensor 14 is acquired as the state quantity data. Thereby, the machining resistance of the tool 1 can be calculated based on the output data d1 of the first motor 12, the rotation speed data d2 of the tool 1, and the simulation model. By calculating the machining resistance of the tool 1, it is possible to estimate the machining amount of the work W and the variation of the bending amount of the work W.

Further, in the present embodiment, the bending amount fluctuation data of the work W is calculated. As a result, error data indicating the shape error variation of the work W can be calculated based on the control command data output to the third motor 31 and the deflection amount variation data of the work W.

Further, in the present embodiment, the rotation angle data d6 of the work W is acquired as the state quantity data. Thereby, the contact position C between the work W and the tool 1 can be calculated based on the rotation angle data d2 and the work model.

Further, in the present embodiment, the output data d3 of the third motor 31 and the position data d4 of the tool 1 in the feed direction are acquired as the state quantity data. Thereby, the unevenness data on the surface of the work W caused by the chatter vibration can be calculated based on the output data d3 of the third motor 31 and the position data d4 of the tool 1.

In the above-described embodiment, the machining conditions by the tool 1 are feedback-controlled based on the machining state data calculated by the machining state calculation unit 53. For example, the machining state data calculated by the machining state calculation unit 53 may be associated with the serial number of the workpiece (product) and stored in the storage unit 56. For example, the shape data of the final product machined by the machine tool 100 may be stored in the storage unit 56 in association with the time stamp and / or the serial number, or may be stored via the output unit 54. It may be configured to be stored in an external management terminal.

In the above-described embodiment, the machine tool 100 is a grinding device for processing a camshaft or a crankshaft, but the machine tool 100 is not limited to the grinding device. The machine tool 100 may be a general cylindrical grinding machine, a spherical grinding machine, a machining center, or a wire saw.

In the above-described embodiment, the control device 50 is provided in the machine tool 100. The control device 50 may be a device different from the machine tool 100. For example, as in the processing system 1000 shown in FIG. 8, the function of the control device 50 may be provided in the management terminal of the factory. In the machining system 1000 shown in FIG. 8, the machine tool 100C and the management terminal 50C having the function of the control device 50 are connected via the communication device 1500. The management terminal 50C communicates data with the machine tool 100C via the communication device 1500. That is, in the above-described embodiment, at least one function of the state quantity data acquisition unit 51, the state quantity estimation data calculation unit 52, the processing state calculation unit 53, the output unit 54, the processing control unit 55, and the storage unit 56 is machine tool. It may be provided separately from the machine 100C.

1 ... Tool, 2 ... Base member, 10 ... First rotating device, 11 ... Support mechanism, 12 ... First motor, 13 ... Stage member, 14 ... Rotation speed sensor, 20 ... Second rotating device, 21 ... Support mechanism, 22 ... Support mechanism, 23 ... 2nd motor, 24 ... Rotation angle sensor, 30 ... Drive device, 31 ... 3rd motor, 32 ... Position sensor, 40 ... Drive device, 41 ... 4th motor, 50 ... Control device, 51 ... State quantity data acquisition unit, 52 ... State quantity estimation data calculation unit, 52C ... Kalman filter, 53 ... Machining state calculation unit, 54 ... Output unit, 55 ... Machining control unit, 56 ... Storage unit, 60 ... CAD data holding unit, 100 ... Machine, 200 ... Control system, 1000 ... Machining system, AX ... Rotating shaft, BX ... Rotating shaft, C ... Contact position, W ... Work.

Claims (12)

A grindstone that comes into contact with the work and grinds the work,
A first rotating device that supports the grindstone and rotates the grindstone around the first rotating shaft.
A second rotation device that supports the work and rotates the work around a second rotation axis parallel to the first rotation axis.
A drive device that drives the grindstone so as to press it against the work in a direction orthogonal to the first rotation axis.
A state quantity data acquisition unit in which state quantity data of the work and the grindstone are input, and
A state quantity estimation data calculation unit that calculates state quantity estimation data from a simulation model including a device dynamic characteristic model showing the dynamic characteristics of the grindstone and a work model showing the target shape of the work.
It is provided with a machining state calculation unit that calculates machining state data indicating the machining state of the work based on the state quantity data and the state quantity estimation data .
The first rotating device includes a first motor that generates power to rotate the grindstone.
The state quantity data includes the output data of the first motor.
The state quantity data includes rotation speed data of the grindstone.
The state quantity estimation data calculation unit calculates the grinding resistance of the grindstone based on the output data of the first motor, the rotation speed data of the grindstone, and the simulation model.
The drive device includes a third motor that generates power to move the grindstone or the work in the feed direction.
The machining state calculation unit calculates the deflection amount fluctuation data of the work or the grindstone based on the grinding resistance and the work model, and the control command data and the deflection amount fluctuation data output to the third motor. Based on, the shape error variation of the work is calculated,
The state quantity data includes the output data of the third motor and the position data of the grindstone in the feed direction.
The processing state calculation unit calculates the unevenness of the surface of the work based on the output data of the third motor and the position data.
Grinding device. The grinding apparatus according to claim 1, further comprising an output unit that outputs the processing state data in the grinding process using the grindstone. The grinding apparatus according to claim 1 or 2, further comprising a machining control unit that controls machining conditions by the grindstone based on the machining state data. The second rotating device includes a second motor that generates power to rotate the work.
The state quantity data includes rotation angle data of the work.
The grinding apparatus according to any one of claims 1 to 3, wherein the state quantity estimation data calculation unit calculates a contact position between the work and the grindstone based on the rotation angle data and the work model. .. The grinding apparatus according to claim 1 or 2 , wherein the work model further includes dynamic characteristic data of the work. The grinding apparatus according to claim 5 , wherein the work model further includes physical property data. The grinding apparatus according to claim 5 or 6 , wherein the work model further includes cross-sectional shape data of the work. A grindstone that comes into contact with the work and grinds the work,
A first rotating device that supports the grindstone and rotates the grindstone around the first rotating shaft.
A second rotation device that supports the work and rotates the work around a second rotation axis parallel to the first rotation axis.
A drive device that drives the grindstone so as to press it against the work in a direction orthogonal to the first rotation axis.
A state quantity data acquisition unit in which state quantity data of the work and the grindstone are input, and
State quantity estimation data calculation to calculate state quantity estimation data from a simulation model including a device dynamic characteristic model showing the dynamic characteristics of the grindstone and a work model showing the dynamic characteristics for calculating the target shape of the work and the deflection amount fluctuation data of the work. Department and
A grinding apparatus including a machining state calculation unit that calculates machining state data including deflection amount fluctuation data of the work indicating the machining state of the work based on the state quantity data and the state quantity estimation data. To grind the work with the grindstone by bringing the work of the columnar member into contact with the grindstone.
Acquiring state quantity data of the work and the grindstone in the grinding process,
To calculate state quantity estimation data from a simulation model including a device dynamic characteristic model showing the dynamic characteristics of the grindstone and a work model showing the target shape of the work.
Calculation of machining state data indicating the machining state of the work based on the state quantity data and the state quantity estimation data, and
Outputting the processing state data in the grinding process and
Look containing a and controlling the processing condition according to the grindstone on the basis of the machining state data in said grinding,
In the grinding process
The grindstone is rotated around the first rotation axis by the first rotation device, and the grindstone is rotated.
The work is rotated around a second rotation axis parallel to the first rotation axis by the second rotation device.
The grindstone is pressed against the work by the drive device in a direction orthogonal to the first rotation axis.
The first rotating device includes a first motor that generates power to rotate the grindstone.
The state quantity data includes the output data of the first motor.
The state quantity data includes rotation speed data of the grindstone.
The grinding resistance of the grindstone is calculated based on the output data of the first motor, the rotation speed data of the grindstone, and the simulation model.
The drive device includes a third motor that generates power to move the grindstone or the work in the feed direction.
The bending amount fluctuation data of the work or the grindstone is calculated based on the grinding resistance and the work model, and the bending amount fluctuation data of the work is calculated based on the control command data output to the third motor and the bending amount fluctuation data of the work. Calculate the shape error fluctuation,
The state quantity data includes the output data of the third motor and the position data of the grindstone in the feed direction.
Based on the output data of the third motor and the position data, the unevenness of the surface of the work is calculated.
Manufacturing method of the work piece. A claim including extracting the machining start point of the work based on the output data from the first motor that generates the power to rotate the grindstone and the rotational speed data from the rotational speed sensor that detects the rotational speed of the grindstone. Item 9. The method for manufacturing a processed product according to Item 9. The state quantity estimation data includes the grinding resistance of the grindstone.
Method for producing a workpiece according to claim 9 or claim 10 comprising estimating a wear amount of the grinding wheel based on the number of the work that has been processed by the grindstone and the grinding resistance. A grindstone that comes into contact with the work and grinds the work,
A first rotating device that supports the grindstone and rotates the grindstone around the first rotating shaft.
A second rotation device that supports the work and rotates the work around a second rotation axis parallel to the first rotation axis.
A drive device that drives the grindstone so as to press it against the work in a direction orthogonal to the first rotation axis.
A state quantity data acquisition unit in which state quantity data of the work and the grindstone are input, and
A state quantity estimation data calculation unit that calculates state quantity estimation data from a simulation model including a device dynamic characteristic model showing the dynamic characteristics of the grindstone and a work model showing the target shape of the work.
It is provided with a machining state calculation unit that calculates machining state data indicating the machining state of the work based on the state quantity data and the state quantity estimation data .
The first rotating device includes a first motor that generates power to rotate the grindstone.
The state quantity data includes the output data of the first motor.
The state quantity data includes rotation speed data of the grindstone.
The state quantity estimation data calculation unit calculates the grinding resistance of the grindstone based on the output data of the first motor, the rotation speed data of the grindstone, and the simulation model.
The drive device includes a third motor that generates power to move the grindstone or the work in the feed direction.
The machining state calculation unit calculates the deflection amount fluctuation data of the work or the grindstone based on the grinding resistance and the work model, and the control command data and the deflection amount fluctuation data output to the third motor. Based on, the shape error variation of the work is calculated,
The state quantity data includes the output data of the third motor and the position data of the grindstone in the feed direction.
The processing state calculation unit calculates the unevenness of the surface of the work based on the output data of the third motor and the position data.
Grinding system.

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