KR20090056706A - The method of in process chucking miss, tool wear and breakage machine tools - Google Patents

Abstract

A method of in process chucking miss, tool wear and breakage machine tools is provided to improve productivity by notifying a user of problem of each of tool in a machine tool using a sensor processor. A method of in process chucking miss, tool wear and breakage machine tools comprises a step of obtaining consumption power by checking a current sensor and a processing voltage in a main shaft or a servo shaft of a machine tool together, and connecting a sensor processor log-calculating the value; a step of automatically storing graph data according to a tool type in case of not selecting the process; and a step of storing alarm history after the former steps or verifying entire steps.

Description

The method of in process chucking miss, tool wear and breakage machine tools}

The present invention relates to a method for detecting a defect generated between a tool and a material and a machining program during machining of all machine tools having numeric control.

More specifically, as shown in FIGS. 2 and 3, data obtained through the sensor processor KH-30 that checks the current sensor KH-20 and the driving voltage KH-10 together with the main shaft or the servo shaft. You can check the effective processing load (KH100) generated between tool and material during in-process. Through such a function, real-time detection of process misses due to missing materials, tool wear and breakage and machine program errors can be detected and connected to a computer system as shown in FIG. It is about a method.

In general, the production situation between the tool and the material of the machine tool is rampant with the following problems.

-After the user has processed the product, check the product visually or perform frequent and full inspection.

         Only through

-The number of tools according to the skill of mounting the tool on the tool post according to the skill of the user

         There is a difference.

-Whether it would be good for the user to directly touch the state of the tool during operation

         Sweet.

-Constant supply of materials and tools supplied by the company regardless of the condition

         Set old life.

-Most of the tool probe devices installed in the machine tool have some cycle in the post process.

         Time interference

-Ambiguous tool cost management for machining between user and manager (user governance)

         Do.

In addition, the conventional method for detecting the state occurring between the tool and the workpiece of the machine tool is divided into four types as follows representatively, but the problem in terms of performance and function to operate in the field.

The first example is to detect the maximum motor load of the machine through test operation using the attached load meter or machine current using the CNC controller of some machine tools, and the tool under the condition that the current load is higher than the maximum load during normal machining. It has been consistent with the method of stopping the equipment due to breakage. However, the disadvantage of this method is that even though the load due to the actual machining does not reflect the machining voltage of the main shaft or the servo shaft, the detection sensitivity is remarkably weak, resulting in a large tool breakdown (drill only, no insert type applicable). May be possible, but it is disadvantageous in that the detection is poor in the case of bad mounting of the material or in the phenomenon of the tool wear. In addition, although the tool may be partially chipped or damaged during the actual machining, the overload may occur. However, if the tool is severely damaged, it may be impossible to detect if the spindle motor and the servomotor have no load despite the machining.

In the second example, when machining is started for each tool, the detection range is not only monitored by defining the processing load due to the PLC DATA operating system of the machine tool, but is also displayed as a whole, including idle and feed sections, which should not be detected unnecessarily. Is that

In the third example, a tool-specific stop function is possible, but the tool-specific stop type cannot be selected. Due to the processing characteristics, such as a bad mounting of the material, if the machine tool is not immediately erected before processing, the headstock may crash, or the tool and the caster may be damaged at the same time as the problem of the tool. In addition, if the machine tool is immediately set up by overload detection during machining, the tool may dig into the workpiece, and it may be made defective even though it can be made good by reworking and correcting. The conventional stop type does not have the ability to stop immediately before the next tool is entered and after machining is complete, in addition to the ability to immediately raise when a problem occurs.

  In the fourth example, the load meter of the machine is significantly lower in response time (response time: 1.5 ms or more, minimum detection requirement (test conclusion): 3 ms or more) compared to the direct current sensor method, and offset according to temperature changes. Shift (% / ° C minimum requirement: ± 0.5) reacts erratically.

Therefore, by using a sensor, which is a scientific and objective method to solve these problems, it is necessary to accurately detect the phenomenon occurring between the tool and the material during machining. In addition to being able to be set up, the user should be able to set up the detection functions easily and at the same time be able to select the stop types due to the nature of the process, and provide a way for the operator to quickly identify the problem tool number. The purpose is to.

The present invention relates to a method for detecting a defect generated between a tool and a material and a machining program during machining of all machine tools having numeric control.

More specifically, as shown in FIGS. 2 and 3, through the data obtained through the sensor processor KH-30 which checks the current sensor (KH-20) and the processing voltage (KH-10) together with the main shaft or the servo shaft. Valid machining loads generated between the tool and material during in-process Through such a function, real-time detection of process misses due to missing materials, tool wear and breakage and machine program errors can be detected and connected to the computer system (KH-70) as shown in Figs. The purpose of this is to use a monitoring program.

The present invention does not interfere with the cycle time, and in real time during the process of detecting a process miss due to the missing material (ucking miss), tool wear and tear and machine program error,

2 and 3, connecting the sensor processor for checking the current sensor and the processing voltage together to the machine tool main shaft or the servo shaft three-phase (u phase of uv w), as shown in FIG. connecting the complete machining and tool number identification (KH 130: start, KH140: end) and machine stop signal using the -code signal interface; Repeating the setting when the above step is made and communication setting with the machine tool or detecting multiple machine tools at the same time using the monitoring program of the computer operating system as shown in FIGS. 2 and 4; After the communication setting is made, at least three or more materials are normally processed to obtain a power value for processing as a setting value (reference value, KH100), and if the values are normal;

As shown in FIG. 5, when the user sets a limit line composed of an upper limit line (KH110), a lower limit line, and an essential passage line (KH130) on a part to be detected for each tool with respect to the stored setting value, and manually modifies the set limit line, the width or height is manually set. Adjusting and storing the machine stop type when violating the limit line; A test step of checking whether the limit line setting for the set value of the step is correct or operating; Or a step of automatically storing the graph data for each tool during the selection and processing of the monitoring function when the process is not selected; After the step is characterized in that the alarm history is made of a storage or full confirmation step.

The present invention, unlike the indirect detection method (eg, road meter, machine current) using a conventional CNC, the phenomenon that occurs between the tool and the material of the machine tool is more reliably detectable, as shown in Figure 2 and 3 machine tool spindle or servo axis By using a sensor processor that checks the current sensor and the process voltage together in three phases (u phase of uv w), processing is no longer performed in accordance with various types of machine stop types that are forced (feed fed) and messages (eg warning lights) in real time. By notifying the user which tool has a problem on a machine tool, the user can prevent defects in advance or prevent mass defects that are missed, and efficient tool life can be managed to increase the maximum production rate. can do.

Also, as shown in FIGS. 2 and 3, the power value obtained by checking the current sensor and the processing voltage together on the three phases of the machine tool or servo shaft (u phase of uv w) is visualized for easy identification by a user using a general monitor. By showing the set machining start (KH130) and end (KH140) for each tool using the M-code signal, it is possible to quickly recognize the production process in which the problem occurs. In addition, with the ability to check the processing status of the entire product, the problem of delivery of defective materials and tools can be objectified, and there is an advantage of tracking back the defect history. The monitoring program can centrally control the tool status of multiple machine tools.

Hereinafter, the present invention will be described in detail with reference to the accompanying drawings.

2 and 3 show a current sensor (KH-20) already selected on the three phases (u phase of uv w) of the machine tool spindle or servo shaft according to the characteristics of the machine tool and the purpose of detection when the machine tools are to be detected simultaneously or in a selected manner. ) And the sensor processor (KH-30) that checks the driving voltage (KH-10) together are connected to the channel controller (KH-40) appropriate for the corresponding machine tool through separate communication cables. In particular, unlike the current consumption method using current sensors, the drive voltage (KH-10) and the current sensor (KH-20) of the main shaft and servo motor are calculated together and reflected in the power consumption. This is because a logarithmic decay rate (log) is applied to detect the state of the tool. Through this, in the present invention, a sensitive response to the weak change in power consumption due to tool wear is output as a graph KH120 on the monitoring program as shown in FIG. 5.

After the state is established, the above-mentioned channel controller (KH-50) can be used to connect the relay connected to the M-code of the machining program of the machine tool as shown in FIG. 2 and use the tool number identification signal (KH-50). KH-40). In addition, a warning light and a stop signal (KH-60) for mechanical feed hold are additionally connected to the channel controller (KH-40).

Next, when the above-described electrical wiring work is completed, the user first executes the monitoring program using a computer and a monitor based on the monitoring program processor of FIG. 1, and automatically corresponds to the first category "environment setting". Select the sensor, enter the machine tool name for easy identification, and connect the channel controller (KH-40) wirelessly or by wire (KH-80) to set the communication port. If multiple machine tools are detected, repeat the above method.

Next, select the second category “Settings” to obtain at least three materials with the user's visual inspection and normal new tools to obtain the settings (reference values) for monitoring which should be stored in the monitoring program. Should be processed normally. After that, it is processed normally at the user's judgment, and if the processing value storage is determined to be correct, the setting is made. However, this part is very important. First of all, if the standard is set by the excessive or small amount of processing, the error range of the set value may be out of range.

In addition, at least three materials must be processed. The first one is to calculate the total machining, tool number recognition and machining time, and the second is to obtain the setting value (reference value). The number of machining set from the second time is automatically stored as the average value excluding the highest and lowest values from the monitoring program. When machining, the tool number is recognized and displayed on this screen from the second time.

Then, if the setting value is calculated and stored, the limit line (for the part KH100) to be detected as shown in FIG. Select the upper limit, the lower limit, and the required passing line, and select and save the machine stop type (immediately, after processing or after processing) due to the processing characteristics if the limit line is violated. It is a function that generates an alarm at the end of the limit setting. It is intended to prevent a process drop or to detect a tool break during machining.

After the process-specific settings are completed, the user can select the fourth category, "Test" or the fifth category, "Monitoring." The function of the test is monitoring without alarm. Using this function, the user can check whether the tool setting is done properly or view the individual or cumulative monitoring graph every time the machining tool is processed. The cumulative graph function indirectly recognizes the limit of tool life. Can be used to set limits.

If the user does not select the fourth category “test” and wants to monitor immediately after “process setting”, he can select the fifth category “monitoring” directly. In this category, a number appears in the identification window for each tool during machining, the monitoring function can be turned off during monitoring, and the alarms that have occurred can be checked and deleted. In addition, if the user wants to save and print the entire machining history, he can do the whole processing history or the selected process processing history, the whole tool or the selected tool only.

The last six categories, “Alarm History”, allows users to re-check the alarms that have been generated so far, by date, and save or print them in removable memory. If you look up the alarm history, you can guess the cause of the defect that has occurred so far. Alarm history is recorded in detail by machine, tool, date and time.

1 is a monitoring program processor flowchart according to the present invention.

  2 is a concept of a monitoring system according to the present invention.

  3 is a connection diagram of a sensor processor according to the present invention.

  4 is a block diagram of a channel processor according to the present invention;

  5 is an example of a limit line section setting method used in the present invention.

Claims (1)

In detecting process misses due to material miss, tool wear and breakage and machine program error in real time during machining without interrupting the cycle time, the machine tool spindle or servo axis three-phase connecting the sensor processor (KH-30) for calculating power consumption by checking the current sensor (KH-20) and the processing voltage (KH-10) together with the u phase of uv w; 2 and 4, after the above step, using the M-code signal interface of the machine tool, the overall machining and tool number identification (KH130: start, KH140: end) and the alarm signal generated from the monitoring program, the warning light and the machine stop signal ( Connecting the feed hold, KH-60) together; Repeating the setting when the above step is made and communication setting with the machine tool or detecting multiple machine tools at the same time using a monitoring program of a computer operating system; After the communication setting is made, at least three or more materials are normally processed to obtain a power value for processing as a setting value (reference value, KH100), and if the values are normal;  When the user sets a limit line composed of an upper limit line (KH110), a lower limit line, and an essential passage line (KH120) on a part to be detected for each tool with respect to the stored setting value as shown in FIG. Adjusting the height and selecting and storing a machine stop type (immediately, after processing, after processing) if it is outside the range of the limit line; A test step of checking whether the limit line setting for the set value of the step is correct or operating; Or a step of automatically storing the graph data for each tool during the selection and processing of the monitoring function when the process is not selected; After this step, the alarm history (tool, machine, date, time) is stored or made of the entire confirmation step.

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