WO2022163426A1 - 画像処理装置 - Google Patents

画像処理装置 Download PDF

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Publication number
WO2022163426A1
WO2022163426A1 PCT/JP2022/001532 JP2022001532W WO2022163426A1 WO 2022163426 A1 WO2022163426 A1 WO 2022163426A1 JP 2022001532 W JP2022001532 W JP 2022001532W WO 2022163426 A1 WO2022163426 A1 WO 2022163426A1
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WO
WIPO (PCT)
Prior art keywords
tool
inspection
area
unit
image
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/JP2022/001532
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English (en)
French (fr)
Japanese (ja)
Inventor
純一 窪田
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
DMG Mori Co Ltd
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DMG Mori Co Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by DMG Mori Co Ltd filed Critical DMG Mori Co Ltd
Priority to CN202280012666.1A priority Critical patent/CN116802014A/zh
Priority to EP22745649.8A priority patent/EP4272895A4/en
Priority to JP2022578260A priority patent/JPWO2022163426A1/ja
Publication of WO2022163426A1 publication Critical patent/WO2022163426A1/ja
Priority to US18/227,955 priority patent/US20230377128A1/en
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23Q—DETAILS, COMPONENTS, OR ACCESSORIES FOR MACHINE TOOLS, e.g. ARRANGEMENTS FOR COPYING OR CONTROLLING; MACHINE TOOLS IN GENERAL CHARACTERISED BY THE CONSTRUCTION OF PARTICULAR DETAILS OR COMPONENTS; COMBINATIONS OR ASSOCIATIONS OF METAL-WORKING MACHINES, NOT DIRECTED TO A PARTICULAR RESULT
    • B23Q17/00—Arrangements for observing, indicating or measuring on machine tools
    • B23Q17/24—Arrangements for observing, indicating or measuring on machine tools using optics or electromagnetic waves
    • B23Q17/248—Arrangements for observing, indicating or measuring on machine tools using optics or electromagnetic waves using special electromagnetic means or methods
    • B23Q17/249—Arrangements for observing, indicating or measuring on machine tools using optics or electromagnetic waves using special electromagnetic means or methods using image analysis, e.g. for radar, infrared or array camera images
    • G—PHYSICS
    • G06—COMPUTING OR CALCULATING; COUNTING
    • G06T—IMAGE DATA PROCESSING OR GENERATION, IN GENERAL
    • G06T7/00—Image analysis
    • G06T7/0002—Inspection of images, e.g. flaw detection
    • G06T7/0004—Industrial image inspection
    • G06T7/001—Industrial image inspection using an image reference approach
    • G—PHYSICS
    • G06—COMPUTING OR CALCULATING; COUNTING
    • G06T—IMAGE DATA PROCESSING OR GENERATION, IN GENERAL
    • G06T7/00—Image analysis
    • G06T7/60—Analysis of geometric attributes
    • G06T7/62—Analysis of geometric attributes of area, perimeter, diameter or volume
    • G—PHYSICS
    • G06—COMPUTING OR CALCULATING; COUNTING
    • G06T—IMAGE DATA PROCESSING OR GENERATION, IN GENERAL
    • G06T2200/00—Indexing scheme for image data processing or generation, in general
    • G06T2200/24—Indexing scheme for image data processing or generation, in general involving graphical user interfaces [GUIs]
    • G—PHYSICS
    • G06—COMPUTING OR CALCULATING; COUNTING
    • G06T—IMAGE DATA PROCESSING OR GENERATION, IN GENERAL
    • G06T2207/00—Indexing scheme for image analysis or image enhancement
    • G06T2207/10—Image acquisition modality
    • G06T2207/10016—Video; Image sequence
    • G—PHYSICS
    • G06—COMPUTING OR CALCULATING; COUNTING
    • G06T—IMAGE DATA PROCESSING OR GENERATION, IN GENERAL
    • G06T2207/00—Indexing scheme for image analysis or image enhancement
    • G06T2207/20—Special algorithmic details
    • G06T2207/20021—Dividing image into blocks, subimages or windows
    • G—PHYSICS
    • G06—COMPUTING OR CALCULATING; COUNTING
    • G06T—IMAGE DATA PROCESSING OR GENERATION, IN GENERAL
    • G06T2207/00—Indexing scheme for image analysis or image enhancement
    • G06T2207/20—Special algorithmic details
    • G06T2207/20092—Interactive image processing based on input by user
    • G—PHYSICS
    • G06—COMPUTING OR CALCULATING; COUNTING
    • G06T—IMAGE DATA PROCESSING OR GENERATION, IN GENERAL
    • G06T2207/00—Indexing scheme for image analysis or image enhancement
    • G06T2207/30—Subject of image; Context of image processing
    • G06T2207/30108—Industrial image inspection
    • G06T2207/30164—Workpiece; Machine component

Definitions

  • the present invention relates to tool inspection technology for machine tools.
  • Machine tools include devices that cut workpieces into desired shapes and devices that create workpieces by laminating metal powder.
  • Machine tools for cutting include a turning center that processes the work by placing a cutting tool against the rotating work, and a machining center that processes the work by placing a rotating tool against the work, combining these functions.
  • the tool is fixed to the tool holder such as the spindle or tool post.
  • a machine tool processes a workpiece while exchanging tools and moving a tool holder according to a machining program prepared in advance.
  • a tool entangled in chips must be replaced with another tool of the same type. After replacement, machining is continued with a new tool. The operator removes chips from the tool after finishing machining (see Patent Document 1).
  • the tool can often be used continuously. A small amount of chips often spontaneously dislodges from the tool during spindle movement. Since it takes time to replace the tool, it is necessary to appropriately determine whether the tool needs to be replaced according to the amount of chips wrapped around the tool (hereinafter referred to as "wound amount").
  • An image processing device includes a receiving unit that receives a captured image of a tool from a camera, and an area of a region that is at least a predetermined distance away from the center of the tool in the captured image corresponding to the tool. and an inspection unit that determines whether the tool can be used continuously based on the size of the surplus area.
  • An image processing device includes a receiving unit that receives a plurality of captured images from the camera while the camera and the tool move relative to each other in the longitudinal direction of the tool; A calculation unit for calculating difference points between a first area including an area corresponding to a tool and a second area including an area corresponding to a tool in a reference image; and an inspection unit for determining propriety of use.
  • FIG. 4 is a schematic diagram showing the positional relationship among a tool, a camera, and a lighting device in a tool recognition area
  • 1 is a hardware configuration diagram of a machine tool and an image processing device
  • FIG. 1 is a functional block diagram of an image processing device
  • FIG. It is a schematic diagram which shows the positional relationship of a tool and an imaging area.
  • FIG. 4 is a schematic diagram of a captured image during a preliminary inspection
  • FIG. 5 is a schematic diagram for explaining a method of calculating the number of black pixels of a reference tool during preliminary inspection
  • FIG. 10 is a schematic diagram of a captured image during a winding inspection
  • FIG. 10 is a schematic diagram for explaining a method of calculating the number of black pixels of a used tool at the time of wrapping inspection; It is a screen diagram of a reference tool imaging screen. It is a screen figure of a use tool imaging screen. 7 is a graph showing the relationship between the amount of winding and the number of black pixels; It is a graph which shows the relationship between the winding amount and the number of difference pixels. 4 is a flow chart showing the process of wrapping inspection.
  • FIG. 15 is a flow chart showing details of an image inspection in S26 of FIG. 14;
  • FIG. It is a schematic diagram of the captured image at the time of the preliminary inspection in a modification. It is a screen figure of an inspection setting screen. It is a 1st screen figure of the used tool imaging screen in a modification. It is a 2nd screen figure of the used tool imaging screen in a modification. It is a 3rd screen figure of the used tool imaging screen in a modification.
  • FIG. 1 is an external view of a machine tool 100.
  • FIG. A machine tool 100 according to the present embodiment is a multitasking machine that processes a work placed within a processing area 200 .
  • a workpiece is fixed to a holder 104 and cut by a tool 102 attached to a main shaft, which is another holder.
  • a holding portion 104 that holds a work is rotationally driven by a driving mechanism.
  • the lower lighting device 108 illuminates the tool 102 and the upper camera 106 images the tool 102 .
  • Tool registration, tool inspection, preliminary inspection, and winding inspection, which will be described later, are performed based on the captured image at this time.
  • the configuration of the tool recognition area 210 is further detailed in connection with FIG. 2 below.
  • the machine tool 100 has a cover 202 that blocks the outside.
  • Cover 202 includes door 204 .
  • a user opens the door 204 to attach a work to the processing area 200 and take out the work from the processing area 200 .
  • the operation panel 206 receives various operations for the machine tool 100 from the operator.
  • the operation panel 206 is connected to the image processing device 110 .
  • a worker can remotely monitor the working status of the machine tool 100 using the image processing device 110 .
  • the main body of the machine tool 100 and the image processing device 110 are connected via a wired cable.
  • Image processing device 110 may be formed as an internal device of machine tool 100 , for example, operation panel 206 .
  • the tool storage unit 130 stores a plurality of tools 102.
  • a tool changer (to be described later) acquires a tool 102 from a plurality of tools 102 stored in the tool storage 130 and mounts it on the spindle.
  • the Y-axis and Z-axis are set in the horizontal direction
  • the X-axis is set in the vertical direction.
  • the Z-axis direction corresponds to the axial direction of the spindle and the work.
  • FIG. 2 is a schematic diagram showing the positional relationship among the tool 102, the camera 106 and the illumination device 108 in the tool recognition area 210.
  • the tool 102 includes a blade portion 112 used for machining a workpiece and a shank portion 114 fixed to a holder 118 of a spindle 116 .
  • the spindle 116 is configured to be rotatable and movable while holding the tool 102 .
  • the spindle 116 can also rotate the tools it holds.
  • the camera 106 includes an image sensor (imaging device) such as CMOS (Complementary Metal Oxide Semiconductor) or CCD (Charge-Coupled Device).
  • the camera 106 images the tool 102 attached to the spindle 116 from above (in the X-axis direction).
  • the camera 106 is connected to the image processing device 110 and the captured image is transmitted to the image processing device 110 .
  • Camera 106 is fixed in tool recognition area 210 .
  • the tool 102 By rotating the tool 102 with the main shaft 116 around the Z-axis, the tool 102 can be imaged from multiple directions. Further, by moving the tool 102 in the horizontal direction (YZ direction) with the spindle 116, it is possible to image a plurality of locations of the tool 102.
  • a lighting device 108 is fixed at the bottom so as to face the camera 106 .
  • a lighting device 108 illuminates the tool 102 from below. Transmitted illumination by the illumination device 108 allows the camera 106 to acquire a high-contrast captured image that facilitates grasping the contour position of the tool 102 .
  • tool registration When the user newly registers the tool 102 (hereinafter referred to as "tool registration"), the operation panel 206 is set to tool registration mode, and the new tool 102 is attached to the spindle 116 .
  • a spindle 116 moves and rotates the tool 102 and a fixed camera 106 automatically images the tool 102 from various positions and orientations.
  • a tool shape is recognized from a large number of captured images obtained by the camera 106, and the tool ID and the tool shape are associated and registered. With such a control method, the tool shape can be automatically associated with the tool ID and registered for each tool 102 .
  • the tool geometry is formed as two-dimensional data or three-dimensional data.
  • the spindle 116 when inspecting the tool 102 during machining or after machining, the spindle 116 causes the tool 102 to enter the tool recognition area 210 . As in new registration, the spindle 116 moves and rotates the tool 102, and the camera 106 automatically captures images of the tool 102 from various positions and directions. A tool shape is recognized from a large number of captured images obtained by the camera 106 . Hereinafter, such an inspection that is appropriately performed during machining will be referred to as a "tool inspection". The operator compares the tool shape data at the time of tool registration and the tool shape data at the time of tool inspection to determine the degree of wear of the tool 102 and the presence/absence of chipping.
  • the camera 106 in this embodiment has a resolution of approximately one million pixels (1224 ⁇ 1024).
  • the imaging range is about 300 mm ⁇ 300 mm.
  • the camera 106 can acquire a maximum of 80 captured images per second.
  • the machine tool 100 in this embodiment also performs a "wrapping inspection" for inspecting the amount of chips wrapped around the tool 102, in addition to the tool inspection for determining whether the tool 102 is damaged or the like.
  • the wrap inspection will be mainly described below.
  • FIG. 3 is a hardware configuration diagram of the machine tool 100 and the image processing device 110.
  • Machine tool 100 includes an operation controller 120 , a machining controller 122 , a machining device 124 , a tool changer 126 and a tool storage 130 .
  • a machining control unit 122 functioning as a numerical controller transmits a control signal to the machining device 124 according to a machining program.
  • the processing device 124 moves the spindle 116 according to instructions from the processing control unit 122 to process the workpiece.
  • the operation control device 120 includes an operation panel 206 and controls the processing control section 122 .
  • the tool storage section 130 stores tools.
  • the tool changer 126 corresponds to a so-called ATC (Automatic Tool Changer).
  • the tool exchange unit 126 takes out a tool from the tool storage unit 130 according to an exchange instruction from the machining control unit 122, and exchanges the tool on the spindle 116 with the taken out tool.
  • the image processing device 110 mainly performs image processing such as tool shape recognition. As mentioned above, the image processing device 110 may be configured as part of the operation control device 120 .
  • the image processing device 110 may be a general laptop PC (Personal Computer) or tablet computer.
  • FIG. 4 is a functional block diagram of the image processing device 110.
  • Each component of the image processing apparatus 110 includes a computing unit such as a CPU (Central Processing Unit) and various computer processors, storage devices such as memory and storage, hardware including a wired or wireless communication line connecting them, and a storage device. , and implemented by software that supplies processing instructions to the computing unit.
  • a computer program may consist of a device driver, an operating system, various application programs located in their higher layers, and a library that provides common functions to these programs.
  • Each block described below represents a functional block rather than a hardware configuration.
  • operation control device 120 and the processing control unit 122 also include hardware including computing units such as processors, storage devices such as memories and storages, and wired or wireless communication lines connecting them, and hardware stored in the storage devices and Software or programs that supply processing instructions may be implemented on an operating system separate from the image processing apparatus 110 .
  • Image processing apparatus 110 includes user interface processing section 140 , data processing section 142 , communication section 300 and data storage section 144 .
  • the user interface processing unit 140 receives operations from the operator, and is in charge of user interface processing such as image display and audio output.
  • a communication unit 300 is in charge of communication with the operation control device 120 .
  • the data processing unit 142 executes various processes based on data acquired by the user interface processing unit 140 and data stored in the data storage unit 144 .
  • Data processing unit 142 also functions as an interface for user interface processing unit 140 , communication unit 300 and data storage unit 144 .
  • the data storage unit 144 stores various programs and setting data.
  • User interface processing unit 140 includes an input unit 146 and an output unit 148 .
  • the input unit 146 receives input from the user via hard devices such as a touch panel, mouse, and keyboard.
  • the output unit 148 provides various information to the user through image display or audio output.
  • Output unit 148 includes display unit 138 .
  • the display unit 138 displays various images on the screen.
  • the communication unit 300 includes a receiving unit 304 that receives data from the operation control device 120 and a transmission unit 306 that transmits data and commands to the operation control device 120 .
  • the data processing section 142 includes an area calculation section 150 , an inspection section 152 , a tool change instruction section 154 and an imaging processing section 156 .
  • the imaging processing unit 156 controls the camera 106 to image the tool 102 .
  • the machining control unit 122 moves the spindle 116 directly below the camera 106 , and the imaging processing unit 156 images the tool 102 .
  • the direction of movement of the spindle 116 can also be instructed from the imaging processing unit 156 to the processing control unit 122 .
  • the inspection unit 152 binarizes the captured image into white pixels and black pixels according to the brightness of each pixel of the captured image.
  • the inspection unit 152 controls tool registration, tool inspection, preliminary inspection and winding inspection.
  • the area calculation unit 150 calculates a "surplus area", which will be described later, as the amount of chip wrapping around the tool 102 from the captured images obtained during the preliminary inspection and the wrapping inspection.
  • the inspection unit 152 determines whether the tool can be used continuously based on the surplus area.
  • the tool change instruction unit 154 instructs the machining control unit 122 to change the tool via the operation control device 120. instruct.
  • the machining control unit 122 instructs the tool exchange unit 126 to exchange the tool determined to be abnormal.
  • FIG. 5 is a schematic diagram showing the positional relationship between the tool 102 and the imaging area 170.
  • the imaging area 170 is positioned directly below the light receiving surface of the camera 106 .
  • Camera 106 images objects within imaging region 170 .
  • the machining control unit 122 inserts the tool 102 into the imaging area 170 by moving the spindle 116 . Since the imaging area 170 is smaller than the tool 102, the entire tool 102 cannot be imaged at once.
  • the lens of the camera 106 is enlarged in order to enlarge the imaging area 170, the cost of the camera 106 will increase. Also, if a large camera 106 is installed in the tool recognition area 210, the space in the machining area 200 will be squeezed, which is not preferable. For this reason, in the present embodiment, a method is adopted in which the relatively small camera 106 captures images of the tool 102 a plurality of times and recognizes the shape of the entire tool 102 based on the multiple captured images.
  • the captured image obtained by capturing a part of the tool 102 with the camera 106 will be referred to as a "partial image".
  • the machining control unit 122 moves the tool 102 (main shaft 116) in the Z-axis positive direction, that is, along the longitudinal direction of the tool 102 at a constant speed.
  • the longitudinal direction here means the axial direction of the tool 102 .
  • the longitudinal direction of the tool 102 coincides with the Z-axis direction.
  • the direction of the tool length of the tool 102 coincides with the longitudinal direction.
  • the imaging processing unit 156 constantly monitors the imaging area 170 . A live view image in the imaging area 170 is transmitted from the camera 106 to the image processing device 110 .
  • FIG. 6 is a schematic diagram of an image captured during a preliminary inspection.
  • the inspection unit 152 performs a winding inspection on the tool 102 during or after machining at a predetermined timing.
  • the execution timing of the wrapping inspection is arbitrary, in this embodiment, it is assumed that the wrapping inspection is executed when the continuous use time of a certain tool 102A exceeds a predetermined time, for example, 3 minutes. In other words, when the tool 102A is replaced with another tool 102B when the continuous use time of the tool 102A is less than 3 minutes, the wrapping inspection of the tool 102A is not performed.
  • the tool 102A is determined to be abnormal in the winding inspection, the tool 102A is replaced with a spare tool 102A of the same type, and machining is continued.
  • the inspection unit 152 executes a preliminary inspection that is a prerequisite for the winding inspection after the tool registration is completed.
  • the contents of the preliminary inspection and the winding inspection are basically the same, but the details will be described later.
  • the inspection unit 152 compares the result of the preliminary inspection and the result of the inspection of winding, calculates the amount of winding, and performs abnormality/normal determination based on the amount of winding.
  • FIG. 6 shows an image captured during a preliminary inspection of a certain tool 102A1 (one of the A type tools 102).
  • the X coordinate value of the center line of the tool 102A1 is "X1”
  • the radius of the tool 102A1 is "R”. Therefore, the X coordinate value X2 of the contour of the tool 102A is "X1+R”.
  • the inspection unit 152 After registering the tool 102A1, the inspection unit 152 performs a preliminary inspection on the tool 102A1.
  • the imaging processing unit 156 instructs the operation control device 120 to linearly move the main shaft 116 in the Z-axis direction.
  • the imaging processing unit 156 After detecting the tip of the blade portion 112 in the imaging region 170 (live view image), the imaging processing unit 156 instructs the camera 106 to acquire a captured image (partial image).
  • the camera 106 acquires the first partial image and fixes it in the memory when receiving the instruction.
  • the first partial image is obtained at a predetermined starting position P1.
  • the start position P1 is defined, for example, when the Z distance between the tip point of the tool 102A1 and the center point of the captured image reaches a predetermined value.
  • the processing control unit 122 After acquiring the partial image at the start position P1, the processing control unit 122 slowly linearly moves the spindle 116 (tool 102A1) in the Z-axis positive direction.
  • the imaging processing unit 156 continuously acquires partial images in conjunction with the movement of the tool 102A1.
  • a final partial image is acquired at a predetermined end position P2.
  • a captured image including a partial outline of the blade portion 112 is obtained from the group of partial images obtained from the start position P1 to the end position P2.
  • the area calculation unit 150 sets an inspection region Q as a part of the imaging range for the multiple obtained partial images.
  • the X coordinate of the inspection area corresponds to the range of X1 to X3 and the Z coordinate range of Z1 to Z2.
  • the positions of Z1 and Z2 are arbitrary, but it is desirable that Z2 be set at a position that does not include the shank portion 114 .
  • the entire inspection area Q may be imaged in one imaging.
  • the imaging area 170 is smaller than the camera 106 as in this embodiment, the tool 102 is imaged multiple times by moving the spindle 116, and the imaging processing unit 156 determines the inspection area Q from a plurality of partial images. It suffices to synthesize captured images.
  • the "area corresponding to the tool 102" may be the entire area of the blade portion 112 and the shank portion 114, or may be an area including at least the inspection area Q.
  • FIG. 7 is a schematic diagram for explaining a method of calculating the number of black pixels of the reference tool during preliminary inspection.
  • the area calculator 150 binarizes each pixel of the captured image corresponding to the inspection area Q based on the luminance.
  • each pixel of the captured image is either a black pixel (black pixel) or a white pixel (white pixel).
  • the black pixels are the pixels corresponding to the positions of the tool 102 (hereinafter referred to as "tool pixels").
  • the coordinates (x, z) of the pixels in the captured image corresponding to the inspection region Q are hereinafter referred to as pixel coordinates. Also, x and z here are called X pixel coordinates and Z pixel coordinates, respectively.
  • x1 be the X pixel coordinate corresponding to the central axis of the tool 102A1.
  • n the number of black pixels corresponding to the positions where the X coordinate is X1 (central axis) and the Z coordinates are Z1 to Z2
  • the number of black pixels is 0 outside the contour of the tool 102A1. This is because there is no object reflected in the captured image outside the tool 102A1 (see also FIG. 6).
  • C(x) the number of black pixels detected at the X pixel coordinate x of the inspection area Q.
  • C(x) the number of black pixels detected at the X pixel coordinate x of the inspection area Q.
  • C(x) n when X1 ⁇ x ⁇ X2
  • C(x) 0 when x>X2.
  • various image noises occur when the tool 102A1 is imaged, so C(x)>0 even when x>X2.
  • FIG. 8 is a schematic diagram of a captured image during the winding inspection.
  • the preliminary inspection described in connection with FIGS. 6 and 7 identifies black pixels from inspection area Q of tool 102A1.
  • the inspection unit 152 performs the winding inspection on the tool 102A1 at a predetermined timing.
  • FIG. 8 shows a captured image during the winding inspection of the tool 102A1. Chips 180 adhere to the tool 102A1.
  • the imaging processing unit 156 also instructs the operation control device 120 to linearly move the tool 102A1 in the Z-axis direction. After detecting the tip of the blade portion 112 in the imaging region 170 (live view image), the imaging processing unit 156 instructs the camera 106 to acquire a captured image (partial image). The camera 106 acquires the first partial image and fixes it in the memory when receiving the instruction.
  • the machining control unit 122 linearly moves the tool 102A1 in the positive Z-axis direction.
  • the imaging processing unit 156 continuously acquires partial images in conjunction with the movement of the tool 102A1.
  • the area calculator 150 sets the inspection area Q of the tool 102A in the ranges of X1 to X3 and Z1 to Z2.
  • the inspection area Q for the preliminary inspection and the inspection area Q for the winding inspection are the same range.
  • the area calculator 150 binarizes the captured image and classifies it into black pixels and white pixels. Most of the black pixels at this time correspond to the tool 102A1, but some correspond to the chips 180. FIG.
  • FIG. 9 is a schematic diagram for explaining a method of calculating the number of black pixels of the used tool during the wrapping inspection.
  • a pixel corresponding to the position of the scrap 180 is called a "scrap pixel".
  • C(x) n when X1 ⁇ x ⁇ X2. This is similar to the reference tool.
  • Black pixels detected in the range of X1 ⁇ x ⁇ X2 are tool pixels.
  • x>X2 even when x>X2, in other words, a small number of black pixels are also detected outside the contour of the tool 102A1. This is the debris pixel corresponding to debris 180 .
  • tool pixels detected outside X2 are referred to as "surplus pixels".
  • Most of the surplus pixels are waste pixels, but they may also contain a small number of objects other than chips or noise.
  • a surplus pixel group 190 shown in FIG. 9 indicates a set of surplus pixels. The total number of surplus pixels is called "surplus area”.
  • the area calculation unit 150 obtains the surplus area S1 of the tool 102A1 (reference tool) during the preliminary inspection and the surplus area S2 of the tool 102A1 (used tool) during the winding inspection. Surplus area S2 becomes large, so that there are many winding amounts of the chips 180 with respect to tool 102A1. Incidentally, as shown in FIG. 7, ideally, the surplus area S1 of the reference tool is "0".
  • the inspection unit 152 determines that the tool 102A1 is "abnormal" when S2 (surplus area of tool in use)-S1 (surplus area of reference tool)>threshold value T1. In this case, the tool 102A1 should be replaced with another tool 102A2 of the same type.
  • a captured image of the inspection area Q is acquired for the reference tool.
  • the area calculation unit 150 acquires the brightness value of each pixel (x, z) included in the captured image.
  • the area calculator 150 counts the number of black pixels whose luminance value is equal to or less than a predetermined threshold.
  • a picked-up image of the inspection area Q is acquired in the same manner for the used tool.
  • the area calculation unit 150 acquires the brightness value of each pixel (x, z) included in the captured image.
  • the area calculator 150 counts the number of black pixels whose luminance value is equal to or less than a predetermined threshold.
  • the inspection unit 152 compares the black pixels of the used tool and the black pixels of the reference tool for each coordinate, and counts the number of different pixels.
  • the difference at this time corresponds to "S2-S1".
  • the difference value between the surplus area S2 and the surplus area S1 will be referred to as a “difference pixel number D" or a “difference value D.”
  • the difference value D is greater than or equal to the threshold value T1
  • the tool 102A1 is determined to be abnormal (cannot be used continuously) because the amount of winding is considered to be extremely large.
  • FIG. 10 is a screen diagram of the reference tool imaging screen 230.
  • the imaging processing unit 156 images the tool 102, and the display unit 138 displays the captured image.
  • the reference tool imaging screen 230 is a captured image of the tool 102 on which chips are not wound, for example, the reference tool during the preliminary inspection.
  • the area calculator 150 calculates the surplus area based on the captured image.
  • the display unit 138 may display the surplus area S ⁇ b>1 on the reference tool imaging screen 230 .
  • FIG. 11 is a screen diagram of the used tool imaging screen 220.
  • the used tool imaging screen 220 is a captured image of the tool 102 around which the chips 180 are wound.
  • the area calculator 150 also calculates the surplus area S2 for the used tool.
  • the display unit 138 may display the surplus area S ⁇ b>2 on the used tool imaging screen 220 .
  • the display unit 138 of the image processing device 110 can also display the reference tool imaging screen 230 and the used tool imaging screen 220 side by side. At this time, the display unit 138 displays the surplus area S1 of the reference tool and the surplus area S2 of the used tool, as well as the difference value D therebetween.
  • the operator freely sets the threshold value T1 while comparing the reference tool imaging screen 230 (reference tool) and the used tool imaging screens 220 corresponding to various winding amounts.
  • the input unit 146 receives input of the threshold value T1 and sets it as an internal parameter of the inspection unit 152 . After setting the threshold value T1, the inspection unit 152 determines whether or not the tool can be used continuously based on the threshold value T1.
  • FIG. 12 is a graph showing the relationship between the amount of winding and the number of black pixels.
  • the horizontal axis is the tool radial direction (X-axis direction), and the vertical axis is the number of black pixels for each X pixel coordinate.
  • the black pixels include both tool pixels corresponding to tool 102 and debris pixels corresponding to chip 180 .
  • a graph 231 is the number of black pixels of the tool 102A1 on which almost no chips are wrapped.
  • a graph 232 is the number of black pixels of the tool 102A1 that can be used continuously although chips are slightly wrapped around it.
  • a graph 234 is the number of black pixels of the tool 102A1 that needs to be replaced because a large amount of chips are wrapped around it.
  • the graph in FIG. 12 corresponds to the diagrams schematically shown in FIGS. 7 and 9. FIG.
  • the number of black pixels sharply decreases when the distance from the tool center exceeds R (tool diameter).
  • R tool diameter
  • the number of black pixels remains even if the distance from the tool center is R or more. This is because a large amount of waste pixels are detected outside the tool contour.
  • the reference tool imaging screen 230 even with the tool 102A1 on which chips are not wrapped at all, a small number of surplus pixels are detected. This is because noise occurs due to fluctuations in imaging conditions and binarization of images. Accordingly, a small amount of surplus pixels as noise are also detected in the graph 231 . Even with the reference tool, the surplus area S1 does not actually become zero.
  • FIG. 13 is a graph showing the relationship between the amount of winding and the number of differential pixels.
  • FIG. 13 shows the black pixel difference value D (the number of difference pixels) between the tool 102A1 as the reference tool and the tool 102A1 as the used tool corresponding to the graphs 231, 232 and 234 in FIG.
  • D the black pixel difference value
  • FIG. 14 is a flow chart showing the process of wrapping inspection.
  • the machining control unit 122 moves the spindle 116 to the tool recognition area 210 (S24). After inserting the spindle 116 into the tool recognition area 210, the machining control unit 122 notifies the operation control unit 120 of completion of preparation.
  • the inspection unit 152 performs an image inspection of the tool 102 (S26). Image inspection determines whether or not the tool can be used continuously. Details of the image inspection are described in connection with FIG. 15 below.
  • the display unit 138 When the result of the image inspection is an abnormality determination (Y of S28), the display unit 138 notifies the operator that a large amount or large chips are wrapped around the tool in use (S30). Subsequently, the imaging processing unit 156 instructs the machining control unit 122 to change tools via the operation control device 120 (S32). The tool exchange unit 126 exchanges the used tool (the tool 102A1 with a large amount of chip winding) for the spare tool 102A2 of the same type stored in the tool storage unit 130 .
  • FIG. 15 is a flow chart showing the details of the image inspection in S26 of FIG.
  • the imaging processing unit 156 images the tool 102 and acquires a captured image corresponding to the inspection region Q (S40).
  • the area calculator 150 calculates the surplus area S2 of the used tool, and calculates the difference value D between the surplus area S1 and the surplus area S2 obtained in advance in the preliminary inspection (S42).
  • the inspection unit 152 determines that there is an abnormality (S46).
  • the difference value D is equal to or less than the threshold value T1 (N of S44)
  • the inspection unit 152 determines that the used tool is normal (can be used continuously) (S48).
  • tool change is executed when an abnormality is determined.
  • the machine tool 100 and the image processing device 110 have been described above based on the embodiments. Chips wrapped around the tool 102 may damage the workpiece. On the other hand, if the tool 102 is exchanged even when only a small amount of chips are wound around, the machining efficiency is lowered. According to this embodiment, the image processing device 110 can perform image recognition of the amount of winding of the tool 102 and automatically determine whether or not the tool can be used continuously. According to such a control method, both machining efficiency and safety in the machine tool 100 can be achieved.
  • the operator can intuitively set the appropriate threshold value T1 by referring to the captured image of the tool 102 and the surplus areas S1 and S2 or the difference value D on the reference tool imaging screen 230 and the used tool imaging screen 220.
  • An arbitrary threshold value T2 may be set, and when D2>T2, the inspection unit 152 may determine that the tool 102A1 is abnormal.
  • the image processing device 110 periodically performs tool inspection to determine whether the tool 102 is damaged.
  • the image processing device 110 may instruct the machine tool 100 to perform the wrapping inspection during the tool inspection.
  • the inspection unit 152 of the image processing device 110 may perform the wrapping inspection when some kind of abnormality is detected during processing.
  • an acceleration sensor is built in the spindle 116, and the acceleration is periodically notified from the camera 106 to the image processing device 110.
  • the inspection unit 152 of the image processing device 110 may execute a wrapping inspection when the acceleration of the camera 106 exceeds a predetermined threshold value because there is a possibility that interference of the tool 102 has occurred.
  • a sound-collecting microphone may be provided in the processing area, and the image processing apparatus 110 may perform the wrapping inspection when an abnormal sound (sound of a predetermined volume or more, sound of a predetermined frequency band, etc.) is generated.
  • the winding inspection may be performed at the timing of replacing with another tool 102B.
  • tool 102A2 which is the same type of tool as tool 102A1
  • tool storage section When replacing the tool 102A1 with the tool 102B, a wrap inspection is performed on the tool 102A1.
  • the operation control device 120 sets the status data of the tool 102A1 to "unusable" after the tool changer 126 replaces the tool 102A1 with the tool 102B. The next time the tool 102A1 is required, the tool changer 126 selects the same type of tool 102A2 instead of the unusable tool 102A1.
  • the tool 102A2 When chips are wrapped around the tool 102A2 and an abnormality is determined, the tool 102A2 is also set to "unusable". After completing a series of machining operations, the operator removes chips from the tools 102 that are "disabled” in the tool storage section 130 . Thereafter, the operator may use the image processing device 110 or the operation control device 120 to change the state of the tools 102A1 and 102A2 from “unusable” to "usable”.
  • the position of the tool radius R is set as the boundary line, and the area calculator 150 detects black pixels located outside the boundary line (tool radius R) as surplus pixels.
  • the boundary line between the surplus pixels and the tool pixels is not limited to the tool radius R, and may be arbitrarily set by the operator.
  • the camera 106 is fixed and the tool 102 is imaged by moving the spindle 116 near the camera 106.
  • a movable camera 106 may be used.
  • the data processing unit 142 includes a camera control unit (not shown), and the camera control unit may image the tool 102 by moving the camera 106 to the side of the tool 102 during tool inspection.
  • the transmitter 306 moves the spindle 116 to a predetermined position within the machining area 200.
  • a control signal may then be sent to the operation control device 120 instructing the spindle 116 to rotate at high speed.
  • the rotation speed is arbitrary, it may be set, for example, in the range of about 500 to 2000 rpm.
  • the inspection unit 152 may re-perform the wrapping inspection. The rotational movement of spindle 116 may remove chips 180 from tool 102 .
  • the inspection unit 152 may determine that the tool 102 can be used continuously.
  • the output unit 148 may include a notification unit (not shown).
  • the notification unit may notify the operator of a message such as "chips may be wrapped around the tool.”
  • the notification method may be both or one of voice and text.
  • FIG. 16 is a schematic diagram of a captured image during a preliminary inspection in a modified example. Also in the modified example, the inspection unit 152 performs a winding inspection on the tool 102 during or after machining at a predetermined timing. The inspection unit 152 also executes a preliminary inspection during tool registration.
  • FIG. 16 is an image taken during a preliminary inspection of a certain tool 102A2 (one of the A-type tools 102). Also in FIG. 16, the X coordinate value of the center line of the tool 102A2 is "X1".
  • the inspection unit 152 After registering the tool 102A2, the inspection unit 152 performs a preliminary inspection on the tool 102A2. During the preliminary inspection, the imaging processor 156 linearly moves the main shaft 116 in the Z-axis direction, that is, in the longitudinal direction of the tool 102 .
  • XP be the difference between the coordinate values of the center line of the imaging region and the center line of the tool 102A2.
  • the difference value XP can be arbitrarily set by the user by a method described later.
  • the machining control unit 122 adjusts the main shaft 116 in the X-axis direction according to the difference value XP, and then moves it in the Z-axis direction based on the movement value ZP.
  • the movement value ZP can also be arbitrarily set by the user by a method described later.
  • the imaging processing unit 156 continuously acquires partial images in conjunction with the movement of the tool 102A2. That is, a plurality of partial images are captured during the process of moving the tool 102 in its longitudinal direction.
  • the partial image obtained during the preliminary inspection will be referred to as a "reference image".
  • a plurality of partial images are obtained for the same inspection area Q as during the preliminary inspection.
  • a plurality of partial images are captured in the process of moving 102 in its longitudinal direction.
  • the partial image during the wrapping inspection will be referred to as a "verification image”.
  • the tool 102 is wrapped with chips during the wrap inspection.
  • FIG. 17 is a screen diagram of the examination setting screen 310. As shown in FIG. The user can set the inspection target, inspection range, and detection sensitivity on the inspection setting screen 310 before the preliminary inspection.
  • An examination setting screen 310 is displayed by the display unit 138 .
  • the inspection setting screen 310 includes an inspection selection area 313 , a range setting area 314 and a detection sensitivity setting area 316 .
  • the inspection selection area 313 the user sets the necessity of each of the "breakage inspection" and the "wrapping inspection" as inspection items. In FIG. 17 only the wrapping inspection is selected. The breakage inspection will be described later.
  • the user defines the inspection area Q by setting the difference value XP and the movement value ZP.
  • the detection sensitivity setting area 316 the user selects the inspection sensitivity from "high”, “medium”, and “low”.
  • the inspection unit 152 compares the reference image and the verification image, and determines the size of the chip winding based on the amount of difference in the number of black pixels included in each image.
  • the number of pixels as a threshold is set to T1 for "high”, to T2 (>T1) for “medium”, and to T3 (>T2) for “low”.
  • the "calculation unit” calculates the number of differences (described later) instead of the surplus area to determine the winding. That is, the functional block diagram of the image processing apparatus 110 in the modified example is obtained by changing the "area calculator” in the functional block diagram illustrated in FIG. 4 to "calculator".
  • the calculation unit compares the reference image and the verification image at the same imaging position, and calculates a difference score, which is the difference in the number of pixels between the second region having black pixels in the reference image and the first region having black pixels in the verification image. do.
  • the black pixels referred to here are specified by the same method as described in connection with FIG.
  • the first area may include chips wrapped around the tool 102 as well as the tool body.
  • the second area corresponds only to the tool 102 .
  • the inspection unit 152 determines whether the tool 102 is normal (can be used continuously) according to the difference score, which is the difference in the number of black pixels between the first area and the second area. If chips are not wrapped around, ideally the first area and the second area are completely matched, and the difference score is zero. That is, the first area and the second area are areas corresponding to the tool 102 that should be coincident with each other.
  • the user touches the setting button 318 when validating the input setting values.
  • the imaging processing unit 156 and the inspection unit 152 store the set values in the data storage unit 144 .
  • the cancel button 320 When canceling, the user touches the cancel button 320 .
  • the breakage inspection method will be described later, and first, the winding inspection method will be explained with a specific example.
  • FIG. 18 is a first screen diagram of a tool-in-use imaging screen in a modified example.
  • verification images P1 to P4 are acquired.
  • Reference images V1 to V4 (not shown) are obtained in advance at the same imaging positions as the verification images P1 to P4.
  • the calculator compares the second area in the reference image V1 with the first area in the verification image P1. More specifically, the inspection unit 152 regards a black pixel region in the verification image P1 whose lightness is equal to or less than a predetermined threshold as a first region, and a black pixel region in the reference image V1 whose lightness is equal to or less than the threshold as a second region. and the difference score D1 of the number of pixels in the second area.
  • the difference score D1 increases.
  • the difference score D1 is a small value even if the influence of image noise or the like is taken into account. Since D1 ⁇ T1 in FIG. 18, the inspection unit 152 does not detect wrapping in the verification image P1 regardless of whether the detection sensitivity is high, medium, or low. In FIG. 18, chips are hardly wrapped around the tip of the tool 102, so the first region in the verification image P1 almost completely corresponds to the second region in the reference image V1.
  • the difference D4 between the verification image P4 and the reference image V4 is larger than the threshold T1 and smaller than the threshold T3. Therefore, when the verification sensitivity is set to "high (T1)", the inspection unit 152 determines that the tool 102 is not suitable for continuous use because chips are wrapped around the tool 102. FIG. On the other hand, when the verification sensitivity is set to "middle (T2)" or "low (T3)", the inspection unit 152 determines that the tool 102 can be continuously used. The inspection unit 152 sequentially compares the difference points D with the threshold for the verification images P1 to P4, and determines that the tool 102 cannot be used when a difference value exceeding the threshold is detected for any of the verification images.
  • the user can freely set the criteria for continued use of the tool 102 .
  • FIG. 19 is a second screen diagram of the used tool imaging screen in the modified example.
  • the movement value ZP is set larger than that during the inspection shown in FIG. 18, so verification images P1 to P9 and reference images V1 to V9 (not shown) are obtained.
  • a difference score D4 in the number of pixels between the first area of the verification image P4 and the second area of the reference image V4 is larger than the threshold T2 and smaller than the threshold T3. Therefore, when the detection sensitivity is set to "high (T1)" or "middle (T2)", the inspection unit 152 determines that the tool 102 cannot be used continuously. When the detection sensitivity is set to "low (T3)", the inspection unit 152 determines that the tool 102 can be continuously used.
  • FIG. 20 is a third screen view of the used tool imaging screen in the modified example. Also in FIG. 20, since the movement value ZP is set larger than that during the inspection shown in FIG. 18, verification images P1 to P9 and reference images V1 to V9 (not shown) are obtained. A difference score D5 in the number of pixels between the first region of the verification image P5 and the second region of the reference image V5 is greater than the threshold value T3. Therefore, regardless of whether the detection sensitivity is set to "high (T1)", “middle (T2)” or “low (T3)", the inspection unit 152 determines that the tool 102 cannot be used continuously based on the verification image P5. judge.
  • the inspection unit 152 subtracts the number of black pixels included in the second region of the reference image from the number of black pixels included in the first region of the verification image, and when the difference score D is greater than the threshold, the tool 102 It is determined that the amount of chips wrapped around is so large that it is not suitable for continuous use.
  • the inspection unit 152 subtracts the number of black pixels contained in the first region of the verification image from the number of black pixels contained in the second region of the reference image, and obtains the difference score. Compare E to a threshold. When the difference score E is larger than the threshold, the inspection unit 152 determines that the tool 102 is broken to the extent that it is not suitable for continued use.
  • the threshold for breakage inspection also changes according to the settings in the detection sensitivity setting area 316 on the inspection setting screen 310 .
  • the inspection unit 152 compares the reference image and the verification image, which are captured images during tool registration, with the verification images, which are captured images during the winding inspection and the breakage inspection, and and the difference score of the number of pixels in the second area, it is determined whether or not there is chip wrapping or breakage of the tool 102 .
  • the inspection unit 152 determines whether or not the tool 102 can be continuously used based on the user's set value of the detection sensitivity.

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