WO2022190155A1

WO2022190155A1 - Workpiece processing apparatus

Info

Publication number: WO2022190155A1
Application number: PCT/JP2021/008858
Authority: WO
Inventors: 雄基伊藤; 信也熊崎
Original assignee: 株式会社Fuji
Priority date: 2021-03-08
Filing date: 2021-03-08
Publication date: 2022-09-15
Also published as: JPWO2022190155A1

Abstract

This workpiece processing apparatus comprises: a processing program which contains a plurality of process handling commands that are commands for executing processing of a workpiece; a processing execution unit which executes the processing of the workpiece using a processing tool in accordance with the processing program; a detection unit which detects a detectable physical quantity pertaining to the processing of the workpiece; a memory unit which memorizes therein actual detection data actually detected by the detection unit; an association unit in which the actual detection data is detected by the detection unit for each of the process handling commands, the actual detection data is associated with the process handling command, and the associated data is memorized as association data in the memory unit; and a setting unit which, using the association data memorized by the association unit, sets a determination threshold for determining the state of the detectable physical quantity for each of the process handling commands.

Description

Work processing device

This specification relates to a work processing device.

As one type of work processing device, Patent Document 1 discloses a machine tool in which an abnormality of a tool is determined by a tool abnormality detection device. The tool abnormality detection device has a threshold value setting switch. When the threshold value setting switch is turned on, the input data is read until the NC information ends or changes, and the read input data (maximum value or average value ), the threshold used for the abnormality detection operation (abnormality determination) is automatically set. In addition, in this tool abnormality detection device, the abnormality is determined during machining only after the threshold value setting switch is turned off.

JP-A-56-139857

In the tool abnormality detection device described in the above-mentioned Patent Document 1, it is possible to automatically set the threshold value, but unless the threshold value setting switch is turned off, there is a possibility that the abnormality determination will not be performed. A workpiece machining apparatus using such a tool abnormality detection device has a problem of reduced convenience.

In view of such circumstances, the present specification discloses a work processing apparatus capable of automatically setting a judgment threshold used for abnormality judgment and improving convenience.

The present specification includes a machining program having a plurality of machining processing instructions that are instructions for machining a workpiece, a machining execution unit that uses a machining tool to machine the workpiece according to the machining program, a detection unit that detects a detectable physical quantity that is a physical quantity related to machining of the workpiece; a storage unit that stores actual detection data actually detected by the detection unit; an associating unit that detects actual detected data by the detecting unit, associates the actual detected data with the processing command, and stores the actual detected data as associated data in the storage unit; and uses the associated data stored by the associating unit. and a setting unit for setting a determination threshold value for determining the state of the detectable physical quantity for each processing command.

According to the present disclosure, the work processing apparatus uses the association data that associates the actual detection data with the processing instruction to determine the state of the detectable physical quantity (abnormality determination) for each processing instruction. A threshold can be set. That is, if the work processing device has the association data, it becomes possible to automatically set the determination threshold value without any special operation by the operator. In this way, the work processing apparatus can automatically set the determination threshold used for abnormality determination and improve convenience.

1 is a front view showing a machine tool 10 to which a work machining device is applied; FIG. FIG. 2 is a side view showing the machine tool 10 shown in FIG. 1; 2 is a block diagram showing the machine tool 10; FIG. FIG. 4 is a flow chart showing a program executed by the control device 50 shown in FIG. 3; FIG. 4 is a flowchart showing a program (monitoring range automatic designation subroutine) executed by the control device 50 shown in FIG. 3; It is a figure which shows 50 d of load display screens. It is a figure which shows the axis setting screen 50e. A system setting screen 50f. It is a figure which shows 50 d of load display screens. It is a figure which shows 50 g of axis setting screens. It is a figure which shows 50 h of path setting screens.

(Machine Tools)
An embodiment, which is an example of a machine tool to which the work processing device is applied, will be described below. In each figure below, the directions in the figure are explained using an XYZ coordinate system. In this XYZ coordinate system, the plane parallel to the horizontal plane is the XZ plane. In this XZ plane, the axial direction of main shafts 20a and 20b of the machine tool 10, which will be described later, is referred to as the Z-axis direction, and the direction orthogonal to the Z-axis direction is referred to as the X-axis direction. Also, the direction perpendicular to the XZ plane is referred to as the Y-axis direction.

The machine tool 10 is a work processing device that processes the work W. As shown in FIG. 1, the machine tool 10 includes a main body 11, a pair of main spindles 20a and 20b, a pair of tool rests 30a and 30b, and a pair of work transfer robots (hereinafter simply referred to as robots) 40a and 40b. , and a control device 50 for controlling the spindles 20a, 20b, the tool stands 30a, 30b, and the

work transfer robots

40a, 40b.

The main shaft 20a holds the workpiece W rotatably. The main shaft 20a is rotatably supported by a headstock (not shown) provided in the main body 11 so as to be arranged horizontally along the left-right direction (Z-axis direction) in FIG. A spindle chuck 21 for detachably holding a workpiece W is provided at the tip of the spindle 20a. The spindle chuck 21 has a plurality of gripping claws 21a, and can grip the workpiece W by closing these gripping claws 21a and release the workpiece W by opening them. The opening and closing of the spindle chuck 21 is carried out according to instructions from the control device 50 . The main shaft 20a is rotationally driven by a servomotor 22 (see FIG. 3). The current (driving current) of the servomotor 22 is detected by a current sensor 23 (see FIG. 3), and the detection result (detected current value) is output to the control device 50 which will be described later. The main shaft 20b is configured similarly to the main shaft 20a.

The tool rest 30a is a device that gives a feed motion to the cutting tool 31, which is a processing tool. The tool rest 30a is a so-called turret-type tool rest, and has a tool holder 32 to which a plurality of cutting tools 31 for cutting the workpiece W are mounted. The tool holding part 32 is rotatably supported by a rotary drive part (not shown) and can be positioned at a predetermined cutting position. The tool table 30a and the cutting tool 31 are moved by a tool table moving device 33 along the left-right direction (X-axis direction) and the front-rear direction (Z-axis direction) in FIG.

The tool rest moving device 33 includes an X-axis driving device 33a (see FIG. 3; X-axis driving axis, sometimes simply referred to as X-axis) for moving the tool rest 30a along the X-axis direction, and a tool rest It has a Z-axis drive device 33b (see FIG. 3; it is a Z-axis drive shaft and may be simply referred to as the Z-axis in some cases) for moving 30a along the Z-axis direction. The X-axis driving device 33a is rotationally driven by a servomotor 33a1 (see FIG. 3). The current (driving current) of the servomotor 33a1 is detected by a current sensor 33a2 (see FIG. 3), and the detection result (detected current value) is output to the control device 50, which will be described later. The Z-axis driving device 33b is rotationally driven by a servomotor 33b1 (see FIG. 3). A current (driving current) of the servomotor 33b1 is detected by a current sensor 33b2 (see FIG. 3), and the detection result (detected current value) is output to the control device 50, which will be described later. The tool table 30b is configured similarly to the tool table 30a.

The spindle 20a and the tool rest 30a described above constitute a processing section 35a for processing the workpiece W. The spindle 20b and the tool rest 30b described above constitute a processing section 35b for processing the workpiece W. As shown in FIG.

(robot)
The

robots

40a and 40b are capable of running on the same running platform, respectively, and are capable of loading and unloading the workpieces W to and from the spindles 20a and 20b and the workpiece mounting device 60, respectively. The work placement device 60 is a device capable of placing a work W thereon. on a mounting surface, a reversing/shifting device for reversing or shifting the attitude of the work W carried out from the machine tool 10, and the like.

The robot 40a has a traveling portion 41 for causing itself to travel (movement along the X axis), a gripping portion 42 for detachably gripping the workpiece W, and relatively moving the gripping portion 42 with respect to the traveling portion 41. A gripping portion moving portion 43 is provided. In this embodiment, the robot 40a is, for example, a three-axis orthogonal robot (three-axis gantry robot). The robot 40a is not limited to an orthogonal robot, and may be a vertical articulated robot, a horizontal articulated robot (scalar type robot), or a parallel link robot. The robot 40b is configured similarly to the robot 40a.

(running part)
As shown in FIG. 1, the traveling portion 41 includes a traveling portion slider 41a (which may also be referred to as an X-axis slider), a guide portion 41b which is a traveling platform for guiding and traveling the traveling portion slider 41a, and a traveling portion. A traveling drive device (not shown) is provided for driving the slider 41a to travel.

The gripping portion 42 and the gripping portion moving portion 43 can be mounted on the traveling portion slider 41a. It is reciprocated (linearly moved) along the

The guide portion 41b is provided on the main body 11 and arranged above the main shafts 20a and 20b and the tool stands 30a and 30b. One end (the left end in FIG. 1) of the guide portion 41b extends right above the work placement device 60 installed on the left side of the main body 11. As shown in FIG. The other end (the right end in FIG. 1) of the guide portion 41b extends right above the work placement device 60 installed on the right side of the main body 11. As shown in FIG. A travel drive shaft (X-axis drive shaft) is composed of the travel portion slider 41a and the guide portion 41b. The traveling drive device is provided on the side of the traveling portion slider 41a or the guide portion 41b.

(Grip part)
As mainly shown in FIG. 2, the grip part 42 is rotatably connected to the Y-axis slider 45a via the rotation driving part 42b. The grip portion 42 has a triangular prism-shaped main body 42a having two orthogonal side surfaces and the remaining side surface. One side of the two orthogonal sides is a plane parallel to the XZ plane, and is provided with a robot chuck 42c that detachably holds the workpiece W. As shown in FIG. The other side surface is a plane parallel to the XY plane, and is provided with a robot chuck 42d that detachably holds the workpiece W. As shown in FIG.

The main body 42a is rotatable by the rotation drive section 42b, and each

robot chuck

42c, 42d can be rotated between two positions (Y-axis direction downward position and Z-axis direction inner position). As a result, the gripping unit 42 moves the workpiece W onto the mounting surface facing upward in the Y-axis direction (for example, the mounting surface of the workpiece mounting device 60) by positioning the robot chucks 42c and 42d downward in the Y-axis direction. can be delivered. In addition, by positioning the robot chucks 42c and 42d toward the inner side in the Z-axis direction, the gripping section 42 has a mounting surface facing the front side in the Z-axis direction (for example, the mounting surfaces of the main shaft chucks 21 of the main shafts 20a and 20b). The workpiece W can be delivered to and received from. The robot chucks 42c and 42d have a plurality of gripping claws (not shown), and can grip the workpiece W by closing the gripping claws and release the workpiece W by opening the gripping claws. The robot chucks 42 c and 42 d are opened and closed according to instructions from the controller 50 .

A rotary drive portion 42b provided on the inclined surface of the tip (lower end) of the Y-axis slider 45a is attached (connected) to the remaining side surface of the main body 42a. The remaining side surfaces of the main body 42a are arranged parallel to the inclined surface at the tip of the Y-axis slider 45a. As shown in FIG. 2, the rotary drive section 42b has a rotary drive shaft 42e provided in the rotary drive section 42b and a rotary drive device (not shown) that rotationally drives the rotary drive shaft 42e.

(Grip part moving part)
The gripping portion moving portion 43 moves the gripping portion 42 relative to the traveling portion slider 41a along the horizontal direction (Z-axis direction) and the vertical direction (Y-axis direction) in FIG. The gripping portion moving portion 43 has a Z-axis driving portion 44 that moves the gripping portion 42 along the Z-axis direction, and a Y-axis driving portion 45 that moves the gripping portion 42 along the Y-axis direction.

(Z-axis drive unit)
The Z-axis driving section 44 moves a Z-axis slider 44a slidably attached to the traveling section slider 41a along the Z-axis direction. As shown mainly in FIG. 2, the Z-axis driving section 44 includes a Z-axis slider 44a, a Z-axis guide section 44b for guiding and moving the Z-axis slider 44a, and a Z-axis guide section 44b for moving and driving the Z-axis slider 44a. and a driving device (not shown).

The Z-axis slider 44a can mount the Y-axis driving portion 45 and the gripping portion 42, extends in the left-right direction (Z-axis direction) in FIG. 2, and is guided by the Z-axis guide portion 44b. It is reciprocated (linearly moved) along the Z-axis direction. The Z-axis guide portion 44b is provided on the traveling portion slider 41a. The Z-axis driving device is provided on the Z-axis guide portion 44b or the Z-axis slider 44a.

(Y-axis drive unit)
The Y-axis driving section 45 moves along the Y-axis direction a Y-axis slider 45a (on which the grip section 42 is supported) slidably attached to the Z-axis slider 44a. As shown mainly in FIG. 2, the Y-axis driving section 45 includes a Y-axis slider 45a, a Y-axis guide section 45b for guiding and moving the Y-axis slider 45a, and a Y-axis guide section 45b for moving and driving the Y-axis slider 45a. and a driving device (not shown).

The Y-axis slider 45a can mount the grip portion 42, and extends along the vertical direction (Y-axis direction) in FIG. Reciprocating motion (linear motion) is performed. The Y-axis guide portion 45b is provided on the Z-axis slider 44a. The Y-axis driving device is provided on the Y-axis guide portion 45b or the Y-axis slider 45a.

(Control device)
The control device 50 is a control device that drives and controls the spindles 20a and 20b, the tool stands 30a and 30b, and the

robots

40a and 40b. In particular, the control device 50 performs drive control of the spindles 20a and 20b and the tool rests 30a and 30b. The control device 50, as shown in FIG. 3, is connected to an input device 50a, a display device 50b, a storage device 50c, current sensors 23, 33a2, 33b2 and servo motors 22, 33a1, 33b1. The input device 50 a is provided on the front surface of the machine tool 10 and is used by the operator to input various settings and instructions to the control device 50 . The display device 50b is provided on the front surface of the machine tool 10, and is used to display information such as operating conditions and maintenance conditions to the operator. The storage device 50c stores data relating to the control of the machine tool 10, such as control programs (machining programs), parameters used in the control programs, data relating to various settings and instructions, actual detection data, association data, and the like. (storage unit). The control device 50 has a microcomputer (not shown), and the microcomputer has an input/output interface, a CPU, a RAM and a ROM (all not shown) connected via a bus. The CPU executes various programs to acquire data, detection signals, control information, etc. from the input device 50a, the storage device 50c, and the current sensors 23, 33a2, 33b2, and the display device 50b and the servo motors 22, 33a1, 33b1. to control. The RAM temporarily stores variables necessary for executing the program, and the ROM stores the program.

(workpiece processing)
Further, the processing (cutting) of the work W by the work processing apparatus (machine tool 10) described above will be described along the flowchart shown in FIG. The control device 50 performs processing according to this flowchart.

In step S102, the control device 50 determines whether or not there is an instruction to start machining a new workpiece W (predetermined number) in the machine tool 10. When the machining program for machining the work W has been newly started, the control device 50 determines that there has been an instruction to start machining the work W ("YES" in step S102), and steps the program. Proceed to S104. If the machining program for machining the work W has not been newly started, the control device 50 determines that there has been no instruction to start machining the work W ("NO" in step S102), and The determination process of step S102 is repeatedly performed until there is an instruction to start machining.

In step S104, the control device 50 determines whether or not there is an instruction to end the previously started machining (predetermined number) of the workpieces W. When the machining program has been completed for all the predetermined quantities, the control device 50 determines that there has been an instruction to finish machining the work W ("YES" in step S104), and ends this flowchart. If the machining program has not ended, the control device 50 determines that there has been no instruction to finish machining the workpiece W ("NO" in step S104), and advances the program to step S106.

In step S106, the control device 50 performs machining of the workpiece W according to the machining program (machining executing section). The machining program includes one or more machining instructions (small machining steps) for machining (machining) the workpiece W with the cutting tool 31 and non-machining instructions for not machining the workpiece W, and the control device 50 , processing and non-processing are performed according to the order of the processing program.

Processing includes cutting and grinding. For cutting processing, there is turning processing in which a cutting tool is applied to a rotating work W by using a lathe or turning center, milling processing in which a rotating cutting tool is applied to a fixed work W by using a machining center or milling machine. It includes drilling by applying a rotating drill to a workpiece W fixed by using a machining center or a drilling machine.

The machining processing command is a command (command) for carrying out machining processing. (The machining program is in units of one line, and the number of program lines is 5, 7, 9, and 10 shown in the load display screen 50d of FIG. 6.).

The non-processing instruction includes a designated processing instruction for designating a processing instruction that is the object of determination (load monitoring) of the state of the processing load (detectable physical quantity described later). The specified processing command is, for example, a block containing "M130", which is a command for starting load detection, "M131", which is a command for ending load detection, among the M codes. This is indicated by 6 and 11 program lines shown on the display screen 50d. The load display screen 50d of FIG. 6 shows a case where the maximum value (maximum load) and the average value (average load) of the load detection values are within the normal range.

It should be noted that the M code is an auxiliary function that turns the machine function on and off. Further, "M130" also indicates a place to start load detection and can be called a designated start processing command, and "M131" also indicates a place to end load detection and can be said to be a designated end processing command. A range sandwiched between "M130" and "M131" is defined as a "path" indicating a load monitoring target location. Also, since a path includes a plurality of sub-processes (program lines), it is called an in-process process.

The load display screen 50d includes a program display field 50d1, a maximum load display field 50d2, an average load display field 50d3, a target drive axis display field 50d4, a next pass switch 50d5, a previous pass switch 50d6, a program display operation switch group 50d7, and A return switch 50d8 is provided. The program display column 50d1 is a column for displaying a machining program for each program line (block). The maximum load display field 50d2 is a field for displaying, in each line of the machining program, the maximum load, which is the maximum value among the load data respectively associated with the programs shown in that line. The average load display column 50d3 is a column for displaying the average load, which is the average value of the load data associated with the program shown in each line of the machining program. The target drive axis display field 50d4 is a field for displaying the drive axis of the load data displayed in the maximum load display field 50d2 and the average load display field 50d3. In FIG. 6, the maximum load and average load on the X-axis are displayed for each program line (machining processing command).

The next pass switch 50d5 is displayed as "next M130" and is a switch for indicating the next pass in the machining program in the program display column 50d1. The previous pass switch 50d6 is displayed as "previous M130" and is a switch for indicating the previous pass in the machining program in the program display column 50d1. The program display operation switch group 50d7 is a switch for jumping to the top line, scrolling upward, jumping to the last line, or scrolling downward the program line displayed in the program display column 50d1. have. The return switch 50d8 is a switch for returning from the load display screen 50d to the previous screen.

In step S108, the control device 50 detects the processing load, which is a detectable physical quantity related to the processing of the workpiece W, as actual detection data (detection unit). Specifically, the machining load is a load generated when the workpiece W is cut (machined) by the cutting tool 31, and is a physical quantity (machining resistance) that acts as resistance to machining. Here, the machining load is the force and energy consumed by the workpiece W and the cutting tool 31 (driven side) that generate machining resistance to the driving side (in this embodiment, each servomotor described above). It is the magnitude of , for example, the torque load applied to the drive shaft. Note that the detectable physical quantity is not limited to the machining load, and may be current consumption or power consumption of the servomotor.

In step S108, the control device 50 acquires from the current sensor 23 that detects the drive current of the servomotor 22 for driving the spindle 20a (or 20b), and from the detected current, the machining load of the servomotor 22 (main spindle 20a It is possible to derive the torque load (spindle machining load) applied to For example, the machining load is derived as the machining load corresponding to the detected current by using a map or an arithmetic expression showing the correlation between the drive current and the machining load. This correlation is such that the drive current increases as the machining load increases. As with the spindle machining load, the X-axis machining load, which is the machining load of the servo motor 33a1, and the Z-axis machining load, which is the machining load of the servo motor 33b1, can also be derived.

The processing load is detected every predetermined short time (sampling period in this embodiment is several milliseconds (for example, 8 milliseconds)). The machining load is detected at a plurality of predetermined machining points in a series of machining programs (machining processes). can be detected respectively. That is, even in machining sub-processes corresponding to a plurality of machining processing commands included in the machining program, the machining load is detected at a plurality of predetermined machining points. processing command), it is possible to detect the machining load at the same machining point for each workpiece W. In addition, the machining load can be detected in the machining process during machining (machining process in units of passes (machining processing command)) as well as in the small machining process.

For example, the processing load is detected and stored for each processing point for each processing count. That is, each machining point (sampling point) of the load data (sampling data) of the first workpiece machining and each machining point (sampling point) of each sampling data of the second and subsequent workpiece machining are all the same machining points. be. A machining point is, for example, an arbitrary machining place during a machining step or a machining sub-step (further, a machining step), and may be a machining time, that is, an elapsed time from a machining start time.

In step S110, the control device 50 stores the plurality of detected processing loads (actual detection data) as a series of load data in the storage device 50c (storage unit). Actual detection data are stored at machining points (at sampling intervals) for each workpiece W to be machined. In other words, the load data for each workpiece W can be stored in association with the machining point. That is, the load data can be associated with the machining sub-step (further, the machining process) via the machining point, and can be associated with the machining instruction associated with the machining sub-step. Furthermore, the load data can be associated with machining instructions associated with the machining process. In this way, the control device 50 detects the actual detection data in step S108 (detection unit) for each processing instruction, associates the actual detection data with the processing instruction, and stores the association data in the storage device 50c ( association part). The load data is actually detected data included in the load monitoring range on a block-by-block basis and further on a path-by-path basis (a unit of collecting blocks whose load is to be monitored). Thus, the processing of steps S106 to S110 described above is processing for sampling the load data.

(monitoring range (monitoring section) automatic designation process)
Next, the control device 50 automatically designates a monitoring range for monitoring the state of the processing load (detectable physical quantity) (step S114: automatic designation unit). The monitoring range is a range for monitoring (determining) the state of the machining load (detectable physical quantity) along the machining process (machining program). If the load detection value is within the upper and lower limit value range of the monitoring range (the judgment threshold range defined by the judgment threshold value), the processing load is in a normal state, and the upper and lower limit value range (judgment threshold range) If outside, the processing load is abnormal. The monitoring range is a range from a monitoring start point at which monitoring is started to a monitoring end point at which monitoring is terminated in the direction along the machining process (this range may be referred to as a monitoring section). The monitoring range is defined by an upper limit value and a lower limit value in the direction along the magnitude of the machining load. The abnormal state includes an abnormal state that requires the work to be stopped and a warning state in which the work is not necessary until the work is stopped and a warning is issued while the work is continued.

Specifically, after the process of step S110, the control device 50 advances the program to step S112 and determines whether or not the flag F1 is 1. The control device 50 determines that the flag F1 is "0" from the start of machining of the workpiece W to the end of the automatic designation of the monitoring range, determines "NO" in step S112, and executes the program. Proceed to step S114. When the automatic designation of the monitoring range is completed, the control device 50 sets the flag F1 to "1" (step S118), determines "YES" in step S112, and processes steps S114 and S116. is omitted, and the program proceeds to step S120 and subsequent steps.

The flag F1 is a flag indicating whether or not the automatic designation of the monitoring range has been completed. When the flag F1 is "1", it indicates that the automatic designation of the monitoring range has been completed. When it is "0", it indicates that the automatic designation of the monitoring range has not been completed. Note that the flag F1 is set to "0" when there is an instruction to start machining the workpiece.

Also, in step S116, the control device 50 determines whether or not the automatic designation of the monitoring range has ended. When the automatic designation of the monitoring range is completed, the control device 50 determines "YES" in step S116, advances the program to step S118, and sets the flag F1 to 1. If the automatic designation of the monitoring range has not been completed, the control device 50 determines "NO" in step S116, returns the program to step S114, and executes the automatic designation of the monitoring range.

At step S114, the control device 50 executes the monitoring range automatic designation subroutine shown in FIG. First, the control device 50 automatically sets the monitoring range in step S202. That is, the control device 50 sets the monitoring range for each path (processing instruction group specified by the specified start processing instruction) included in the machining program. Specifically, when a path is included in the machining program, the control device 50 determines that the process during machining by that path is within the monitoring range. , it is determined that the process by that path cannot be the monitoring range. For example, as shown in FIG. 6, the machining program includes "M130", which is the specified start processing command in the M code, so the control device 50 controls the machining corresponding to the path including this specified start processing command. It becomes possible to automatically set the middle process as the monitoring range. In this way, in step S114, the control device 50 can search for a specified processing command and automatically set the processing command specified by the searched specified processing command in the monitoring range.

Note that the monitoring range may be set for each block. Specifically, the control device 50 sets the monitoring range for each processing instruction (block) included in the machining program based on the processing instruction type. Specifically, when a block contains a processing command, the control device 50 determines that the processing sub-steps of that block (processing block) are within the monitoring range. If a non-processing instruction is included, it is determined that the process by that block (non-processing block) cannot be within the monitoring range. For example,

program lines

5, 7, 9, and 10 shown in the load display screen 50d of FIG. Therefore, the control device 50 can automatically set the processing substep corresponding to the block containing this processing execution command as the monitoring range.

In step S204, the control device 50 acquires the load data (machining data) linked (associated) with the machining point and thus the process during machining (or the sub-process of machining) from the storage device 50c. Then, in step S206, the control device 50 associates the automatically preset monitoring range (path) with the load data. The monitoring range (path) is linked (associated) with the processing point, and the load data is also linked with the processing point. As a result, the control device 50 can associate the monitoring range (path) and the load data via the processing points. Consequently, the control device 50 can associate the machining program with the load data. After that, the control device 50 terminates the processing of this subroutine.

(Automatic setting of upper and lower limits of monitoring range (threshold for judgment))
The description proceeds to step S120 and subsequent steps shown in FIG. When the control device 50 is in the judgment threshold automatic setting mode for automatically setting the judgment threshold after the automatic designation of the monitoring range (for example, the automatic setting switch 50e4 (see FIG. 7) is turned on) If so ("YES" is determined in step S124), the upper and lower limits (threshold values for determination) of the specified monitoring range are automatically set (setting unit; step S128). On the other hand, if the determination threshold value automatic setting mode is not set (for example, if the automatic setting switch 50e4 is not turned on (determined as "NO" in step S124)), notification to the effect that the automatic setting switch 50e4 is turned on is provided. It implements (notification part; step S126). Note that the control device 50 can set the operation mode to the determination threshold value automatic setting mode when the automatic setting switch 50e4 is turned on.

In step S124, the control device 50 determines whether or not the operation mode is the determination threshold value automatic setting mode based on whether or not the automatic setting switch 50e4 is turned on. The automatic setting switch 50e4 is a determination threshold value setting switch for automatically setting the determination threshold value in a later-described setting unit (step S128). The automatic setting switch 50e4 is displayed on the axis setting screen 50e shown in FIG. The axis setting screen 50e is a screen displayed on the display device 50b, and is a screen for setting parameters related to drive axes such as the X axis, the Z axis, and the main axes 20a and 20b. The axis setting screen 50e (display device 50b) is a touch panel, and can be input by the operator's operation, so it also functions as an input device. The automatic setting switch 50e4 is a switch that is switched by tapping. When turned "ON", the switch itself appears to be recessed, and when turned "OFF", the switch itself appears to be flattened. The automatic setting switch 50e4 may switch colors.

The judgment threshold is a value for judging the state of the processing load (detectable physical quantity). In this embodiment, the determination thresholds are the upper limit of the maximum load (two types), which is the maximum value of the processing load, the upper limit of the average load (two types), which is the average value of the processing load, and the lower limit of the average load. Adoptable. The upper limit value of the maximum load is divided into an upper limit value for abnormal conditions that is determined to be an abnormal condition that requires the machine tool 10 to stop machining the workpiece, and an abnormal condition that requires a warning without stopping the workpiece machining of the machine tool 10 ( It has a warning upper limit value for determining that it is in a warning state. Like the maximum load upper limit, the average load upper limit also has an abnormal upper limit and a warning upper limit. The lower limit value of the average load is a value determined as an abnormal state (warning state) requiring a warning even before the machining of the machine tool 10 is stopped. Note that the lower limit value of the average load may be a value for determining an abnormal state that requires stopping the machining of the machine tool 10 . Alternatively, the lower limit value of the minimum load, which is the minimum value of the machining load, may be adopted.

In step S126, in order to prompt the operator to press the automatic setting switch 50e4, the control device 50 displays on the display device 50b that the automatic setting switch 50e4 is turned on, or emits a voice message from the speaker. In this manner, the control device 50 notifies the operator to press the automatic setting switch 50e4 when the automatic setting switch 50e4 is not pressed (notification unit).

The automatic setting switch 50e4 is preferably turned on when the machine tool 10 is installed or before the first machining. According to this, when the machining process of the machine tool 10 is performed, the operator is not required to press the automatic setting switch 50e4, and the trouble of pressing the automatic setting switch 50e4 during the machining process can be saved. It becomes possible. It is also possible to omit the installation of the automatic setting switch 50e4 and always automatically set the determination threshold value (always set the determination threshold value automatic setting mode). In this case, the processing of steps S124 and S126 may be omitted.

When the automatic setting switch 50e4 is pressed, in other words, when the judgment threshold value automatic setting mode is set, the control device 50 completes the automatic designation of the monitoring range (monitoring section), and the designated monitoring range is set. Upper and lower limits (threshold values for judgment) are automatically set (step S128). First, the control device 50 performs machining of the workpiece W (workpiece machining) N times, and uses load data (actual detection data) for N times to set the upper and lower limit values (determination threshold) of the monitoring range. Set automatically.

Specifically, the control device 50 performs the first to N-th workpiece machining, stores the load data for each workpiece machining (determines "NO" in steps S120 and S122, respectively), and stores the load data for each workpiece machining. (After determining "NO", "YES" and "YES" in steps S120, 122 and 124, step S128). At this time, in step S128, the control device 50 sets an upper limit value and a lower limit value (determination threshold value) of the monitoring range for each block (machining program line) to be monitored.

In step S128, the control device 50 uses the association data stored in step S110 (association unit) to determine for each machining instruction (program line) during the machining of the workpiece in step S106 (machining execution unit). (setting unit). Specifically, the control device 50 calculates the maximum value (maximum load) and/or the average value (average load) of the load data (actual detection data) for each processing command (see FIG. 6), and calculates A determination threshold is set from the maximum load and/or the average load. The determination threshold can be calculated by adding or subtracting a preset (input) predetermined value to or from the maximum value and/or average value of the actual detection data. The predetermined value can be input by the operator on a screen 50f (system setting screen) shown in FIG. The predetermined value is not limited to input by the operator, and may be received as data. Furthermore, the control device 50 can set the determination threshold for the processing command designated by the designated processing command retrieved in step S114.

As shown in FIG. 8, the system setting screen 50f is a screen for setting a determination threshold value, and is an abnormal value addition value for inputting (setting) an abnormal value addition value that is a predetermined value of an abnormal value. A box 50f1, a warning value addition value box 50f2 for inputting (setting) a warning value addition value that is a predetermined value of the warning value, and a lower limit value addition value that is a predetermined value of the lower limit (setting) A lower limit additional value box 50f3 is provided for this purpose. Numerical input to these boxes 50f1 to 50f3 is performed by the operator, for example, using a ten-key input. In this embodiment, "100" is input to the abnormal value additional value box 50f1, "50" is input to the warning value additional value box 50f2, and "50" is input to the lower limit value additional value box 50f3. ' is entered. It should be noted that it is preferable to input a value larger than the additional value for warning value as the additional value for abnormal value. If the additional value for warning value is greater than the additional value for abnormal value, a warning to that effect may be issued.

The system setting screen 50f also includes an upper limit valid box 50f4 indicating that the setting of the upper limit of the maximum load is valid, an upper limit invalid box 50f5 indicating that the setting of the upper limit of the maximum load is invalid, an average load average value valid box 50f6 indicating that the setting of the upper limit value (average value) of the average load is valid, average value invalid box 50f7 indicating that the setting of the upper limit value (average value) of the average load is invalid, setting of the lower limit value A lower limit valid box 50f8 indicating that the setting of the lower limit is valid and a lower limit invalid box 50f9 indicating that the setting of the lower limit is invalid are provided. When each box is checked by the operator (inputting "@" or "re"), the function indicated by the box becomes valid.

In this embodiment, "@" is entered in the upper limit valid box 50f4, and the automatic setting of the upper limit of the maximum load is valid. Furthermore, "@" is entered in the average value valid box 50f6, and the automatic setting of the upper limit value of the average load is valid. "@" is entered in the lower limit valid box 50f8, and the automatic setting of the lower limit of the average load or the minimum load is valid.

Furthermore, the system setting screen 50f is provided with a save switch 50fa. The save switch 50fa is a switch for saving the valid/invalid setting and the addition value input on the system setting screen 50f. Save the input contents of the addition value.

In step S128, the control device 50 calculates the maximum value (maximum load), the minimum value, and the average value (average load) among the load detection values for N machining points related to the machining command for each machining command. do. Furthermore, the control device 50 can calculate and set an abnormal upper limit value (for maximum load), which is a determination threshold value, by adding the abnormal value addition value to the maximum load for each processing command. The control device 50 can calculate and set a warning upper limit value (for maximum load), which is a determination threshold value, by adding the warning value additional value to the maximum load for each processing command. In addition, the control device 50 can calculate and set an abnormal upper limit value (for average load), which is a determination threshold value, by adding an abnormal value additional value to the average load for each processing command. The control device 50 can calculate and set a warning upper limit value (for average load), which is a determination threshold value, by adding the warning value additional value to the average load for each processing command.

Then, the control device 50 can calculate and set the lower limit value, which is the determination threshold value, by adding the additional value for lower limit value to the average load (or minimum load) for each processing command. The control device 50 can calculate and set the lower limit value, which is the determination threshold value, by adding the additional value for the lower limit value to the average load (or the minimum load) for each processing command. Since the low adder is set to a negative value, adding the low adder to the average load (or min load) will result in subtracting the low adder from the average load (or min load). It is to be.

The set determination threshold can be confirmed on the axis setting screen 50g displayed for each axis, as shown in FIG. In FIG. 10, it is possible to display the determination threshold for the X-axis for each pass. The axis setting screen 50g is provided with a judgment threshold display field 50g1, an axis display field 50g2, a work No. display field 50g3, a program display switch 50g4, and a judgment threshold display operation switch group 50g5. The work No., which is the management number of the work, the tool No. used for machining the work, and the type of drive axis related to machining are associated with the load data.

The judgment threshold value display column 50g1 is a column for displaying the judgment threshold value for each pass. load), the maximum load among the load data used to calculate the threshold for judgment, the upper limit for abnormality (for average load), the upper limit for warning (for average load), the lower limit for warning, and , displays the average load, which is the average of the load data used to calculate the judgment threshold. The axis display field 50g2 displays the axis on which the determination threshold value is displayed (load data is stored). The work No. display column 50g3 displays the management number of the work for which the determination threshold value is displayed (load data is stored). The program display switch 50g4 is a switch for switching the screen to a screen (for example, the load display screen 50d shown in FIG. 6) in which the program line (or path) in which the machining load is detected is displayed. The determination threshold display operation switch group 50g5 has switches for scrolling upward or downward the lines displayed in the determination threshold display column 50g1.

The set determination threshold can be confirmed on the path setting screen 50h displayed for each path, as shown in FIG. In FIG. 11, it is possible to display the determination threshold value for a predetermined path for each axis. The pass setting screen 50h is provided with a judgment threshold display field 50h1, a pass display field 50h2, a work No. display field 50h3, a tool No. display field 50h4, a program display switch 50h5, and a judgment threshold display operation switch group 50h6. .

The determination threshold value display field 50h1 is a field for displaying the determination threshold value for each axis. ), the maximum load among the load data used to calculate the threshold for judgment, the upper limit for abnormality (for average load), the upper limit for warning (for average load), the lower limit for warning, and judgment Displays the average load, which is the average of the load data used to calculate the threshold for The path display column 50h2 displays the path No. for which the determination threshold value is displayed (load data is stored). The work No. display column 50h3 displays the management number of the work for which the determination threshold value is displayed (load data is stored). The tool No. display column 50h4 displays the management number of the cutting tool for which the determination threshold value is displayed (load data is stored). The program display switch 50h5 is a switch for switching the screen to a screen (for example, the load display screen 50d shown in FIG. 6) displaying the program line (or path) in which the machining load is detected. The judgment threshold display operation switch group 50h6 has switches for scrolling upward or downward the lines displayed in the judgment threshold display column 50h1.

It should be noted that the axis setting screen 50g shown in FIG. 10 and the path setting screen 50h shown in FIG. It is possible to highlight and display the location where the abnormal state or warning state has occurred. For example, when the maximum load of the path with the path No. 3 on the X-axis is in an abnormal state, the maximum load column and the abnormal upper limit value ( maximum load) column is highlighted. When the average load of the path whose path number is 4 on the X axis is in a warning state, the average load column and the warning upper limit value (average load ) column is highlighted.

Also, in the axis setting screen 50g shown in FIG. 10 and the path setting screen 50h shown in FIG. 11, it is possible to manually change the determination threshold. The part to be changed can be specified, and the change can be made by inputting with the numeric keypad.

Furthermore, the control device 50 sets the flag F2 to 1 in step S130. The flag F2 is a flag indicating whether or not the upper and lower limit values of the monitoring range have been set by the load data for N times. When the flag F2 is "1", it indicates that the upper and lower limit values of the monitoring range have been set. , and indicates that the upper and lower limits of the monitoring range have not been set when the flag F2 is "0". Note that the flag F2 is set to "0" when there is an instruction to start machining the workpiece.

In step S120, it is determined whether or not the flag F2 is 1. The control device 50 determines that the flag F2 is "0" and "NO" in step S120 until the upper and lower limit values of the monitoring range are set after the machining of the workpiece W is started. When the upper and lower limits of the monitoring range have already been set, the control device 50 sets the flag F2 to "1", determines "YES" in step S120, and omits the processing of steps S122 to S130. The program proceeds from step S132 onwards.

Also, in step S122, it is determined whether or not the above-described workpiece machining, machining load detection, and load data storage have been performed N times. The control device 50 determines that the workpiece machining has not been completed N times after the first workpiece machining is started and before the Nth workpiece machining is completed ("NO" in step S122). ”), and the program returns to step S104. When the Nth workpiece machining is completed, control device 50 determines that the workpiece machining has been completed N times ("YES" in step S122), and advances the program to step S124.

In step S132, the control device 50 determines whether or not the load detection value, which is the processing load detected after setting the threshold for determination, is within the normal range (threshold range for determination) of the monitoring range (monitoring interval). . When control device 50 determines that the load detection value is within the normal range of the monitoring range ("YES" in step S132), control device 50 returns the program to step S104, and performs the series of steps S104 to S110 described above. are carried out according to the order of the machining program. The normal range of the monitoring range is a range smaller than the abnormal upper limit value and the warning upper limit value for the maximum load and greater than the warning lower limit value, and the abnormal upper limit value and the warning upper limit value for the average load. A range that is less than and greater than the lower warning limit.

On the other hand, when control device 50 determines that the load detection value is not within the normal range of the monitoring range ("NO" in step S132), the program proceeds to step S134, and the load detection value is within the abnormal state range. or in the warning state range. In step S134, the control device 50 determines that the load detection value is smaller than the abnormal upper limit value for maximum load and larger than the warning upper limit value for maximum load, or is smaller than the abnormal upper limit value for average load. If the range is greater than the warning upper limit value for average load, it is determined to be within the warning state range ("YES" in step S134), and the program proceeds to step S136 and subsequent steps. After that, the control device 50 issues a warning (step S136), then returns the program to step S104, and continues workpiece machining while issuing a warning.

In the above-described embodiment, in steps S132 and S134, it is determined whether or not the load detection value is within the threshold range for determination. It may be determined whether or not it is within the determination threshold range, and whether or not the average value (average load) of the load detection values is within the determination threshold range for the average load.

Further, in step S134, if the load detection value is in a range larger than the abnormal upper limit value for maximum load or in a range larger than the abnormal upper limit value for average load, the control device 50 determines that the warning state is reached. It is determined that it is within the range ("NO" at step S134), machining of the workpiece W is stopped (step S138), and a warning is issued (step S140), after which this flow chart ends.

In step S136 or step S140, the control device 50 automatically displays the load display screen 50d shown in FIG. In the load display screen 50d shown in FIG. 9, an abnormality is displayed at the maximum load and a warning is displayed at the average load. In either case, the maximum load or average load values are highlighted. In the program of 9 program lines, it is shown that the detected load value exceeded the upper limit value for abnormalities of the maximum load and was judged to be abnormal. In the program of 10 program lines, it is shown that it is determined that a warning is necessary because the load detection value has exceeded the warning upper limit value of the average load.

In this way, the machining program sandwiched between the M code for starting load detection and the M code for ending load detection is extracted, and the maximum load and average load are displayed for each program line of the extracted machining program (for each program line). be able to. Furthermore, it is possible to display together the locations where anomalies occur in the maximum load and the average load. Therefore, since the error occurrence location is displayed for each program line, the operator can refer to the displayed error occurrence location and perform more detailed cause analysis.

(Specification of section of monitoring range and adjustment of threshold for judgment by operator's manual operation)
Note that the control device 50 manually designates a monitoring range (monitoring range section (monitoring section)) from among the monitoring ranges automatically designated in step S114, and also manually designates the designated monitoring range judgment threshold value (monitoring section). It is possible to manually adjust the upper and lower limit values automatically set in step S128 previously. As a result, the operator can perform a series of manual operations to first specify the monitoring range that requires the monitoring function from among the monitoring ranges, and then adjust the judgment threshold for the specified monitoring range. Become. As a result, the monitoring range can be specified and adjusted more easily. Note that the section designation of the monitoring range and the adjustment of the determination threshold value may be performed by separate operations instead of continuous operations.

The determination threshold can be adjusted by the operator's manual input on the axis setting screen 50g shown in FIG. Also, the adjustment of the determination threshold can be performed by the operator's manual input on the path setting screen 50h shown in FIG. In either case, the threshold value for determination to be adjusted may be specified and changed by inputting the numeric keypad.

(Action and effect of the present embodiment)
The work machining apparatus (machine tool 10) according to the above-described embodiment uses a machining program having a plurality of machining processing commands, which are commands for machining a work W, and a cutting tool 31 (machining tool). A machining execution unit (control device 50; step S106) that performs machining of W according to a machining program, and a detection unit that detects a detectable physical quantity (machining load) that is a physical quantity related to machining of the workpiece W. (control device 50; step S108); a storage unit (storage device 50c) that stores actual detection data actually detected in step S108; Using the association unit (control device 50; step S110) that associates the detected data with the processing instruction and stores it in the storage device 50c as association data, and the association data stored in step S110, processing is performed for each processing instruction. and a setting unit (control device 50; step S128) for setting a determination threshold value for determining the state of the load.

According to the present embodiment, the machine tool 10 uses association data that associates actual detection data with processing instructions to determine the state of the processing load (abnormality determination) for each processing instruction. A threshold can be set. That is, if the machine tool 10 has the association data, it becomes possible to automatically set the determination threshold value without any special operation by the operator. In this manner, the machine tool 10 can automatically set the determination threshold used for abnormality determination and improve convenience.

Also, the control device 50 sets a determination threshold from the maximum value or average value of the actual detection data for each processing command (step S128). According to this, it is possible to appropriately set the determination threshold value for each processing command.

Further, in the above-described embodiment, the machining program has a specified processing command for specifying a processing command to be judged, and the control device 50 searches for the specified processing command, and according to the searched specified processing command, A determination threshold can be set for the designated processing command (step S128). According to this, it is possible to automatically set the processing command to be judged, and furthermore to appropriately set the threshold value for judgment of the automatically set processing command.

In the above-described embodiment, the machine tool 10 further includes a determination threshold value setting switch (automatic setting switch 50e4), which is a switch for automatically setting the determination threshold value in the setting unit (step S128). In preparation, the control device 50 sets the determination threshold when the operator presses the automatic setting switch 50e4 (step S128). According to this, when the automatic setting switch 50e4 is pressed by the operator, it becomes possible to switch to the determination threshold value automatic setting mode in which the determination threshold value is automatically set. It is possible to automatically set the threshold for use. As a result, after the determination threshold value is set, it is possible to carry out an abnormality determination during workpiece machining without performing an operation such as switching the setting.

In the above-described embodiment, the control device 50 further includes a notification unit (step S126) that notifies the operator to press the automatic setting switch 50e4 when the automatic setting switch 50e4 is not pressed. According to this, it is possible to ensure that the operator presses down the automatic setting switch 50e4, and it is possible to ensure that the judgment threshold value automatic setting mode is set.

In addition, in the above-described embodiment, a cutting tool is used as a processing tool, but other processing tools for processing the workpiece W may be used. Also, although the machining load is used as the detectable physical quantity, other physical quantity relating to machining of the workpiece W that is detectable may be used.

Further, in the above-described embodiment, the dual gantry type machine tool 10 is provided with two spindles, tool rests and robots. can also be adopted.

10... Machine tool (workpiece processing device), 31... Cutting tool (processing tool), 50... Control device (machining execution unit (step S106), detection unit (step S108), association unit (step S110), setting unit (step S128), reporting section (step S126)), 50c...storage device (storage section), 50e4...automatic setting switch (determination threshold value setting switch), W...work.

Claims

a machining program having a plurality of machining instructions that are instructions for machining a workpiece;
a machining execution unit that uses a machining tool to machine a workpiece according to the machining program;
a detection unit that detects a detectable physical quantity that is a physical quantity related to machining of the workpiece;
a storage unit that stores actual detection data actually detected by the detection unit;
an association unit that detects actual detection data by the detection unit for each processing instruction, associates the actual detection data with the processing instruction, and stores the actual detection data in the storage unit as association data;
a setting unit that uses the association data stored by the association unit to set a determination threshold value for determining the state of the detectable physical quantity for each processing command;
A work processing device equipped with
The work processing apparatus according to claim 1, wherein the setting unit sets the determination threshold from a maximum value or an average value of the actual detection data for each processing command.
The machining program has a designation processing instruction for designating the processing instruction to be determined,
2. The work processing apparatus according to claim 1, wherein the setting unit searches for the specified processing command, and can set the determination threshold for the processing command specified by the searched specified processing command.
further comprising a determination threshold value setting switch, which is a switch for causing the setting unit to automatically set the determination threshold value;
2. The work processing apparatus according to claim 1, wherein the setting unit sets the determination threshold when the determination threshold setting switch is pressed by an operator.
5. The work processing apparatus according to claim 4, further comprising a notification unit that notifies the worker to press the determination threshold setting switch when the determination threshold setting switch is not pressed.