WO2024095382A1 - センサ異常判定装置、センサ異常判定システム、センサ異常判定方法、コンピュータプログラム、非一時的記憶媒体、および工作機械 - Google Patents

センサ異常判定装置、センサ異常判定システム、センサ異常判定方法、コンピュータプログラム、非一時的記憶媒体、および工作機械 Download PDF

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Publication number
WO2024095382A1
WO2024095382A1 PCT/JP2022/040942 JP2022040942W WO2024095382A1 WO 2024095382 A1 WO2024095382 A1 WO 2024095382A1 JP 2022040942 W JP2022040942 W JP 2022040942W WO 2024095382 A1 WO2024095382 A1 WO 2024095382A1
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WIPO (PCT)
Prior art keywords
sensor
data
determination
abnormality
sensors
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PCT/JP2022/040942
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English (en)
French (fr)
Japanese (ja)
Inventor
洋樹 大森
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Sumitomo Electric Industries Ltd
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Sumitomo Electric Industries Ltd
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Priority to PCT/JP2022/040942 priority Critical patent/WO2024095382A1/ja
Priority to JP2023524657A priority patent/JP7405307B1/ja
Publication of WO2024095382A1 publication Critical patent/WO2024095382A1/ja
Anticipated expiration legal-status Critical
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    • 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
    • B23Q17/09—Arrangements for observing, indicating or measuring on machine tools for indicating or measuring cutting pressure or for determining cutting-tool condition, e.g. cutting ability, load on tool
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01D—MEASURING NOT SPECIALLY ADAPTED FOR A SPECIFIC VARIABLE; ARRANGEMENTS FOR MEASURING TWO OR MORE VARIABLES NOT COVERED IN A SINGLE OTHER SUBCLASS; TARIFF METERING APPARATUS; MEASURING OR TESTING NOT OTHERWISE PROVIDED FOR
    • G01D21/00—Measuring or testing not otherwise provided for
    • G—PHYSICS
    • G08—SIGNALLING
    • G08C—TRANSMISSION SYSTEMS FOR MEASURED VALUES, CONTROL OR SIMILAR SIGNALS
    • G08C17/00—Arrangements for transmitting signals characterised by the use of a wireless electrical link

Definitions

  • This disclosure relates to a sensor abnormality determination device, a sensor abnormality determination system, a sensor abnormality determination method, a computer program, a non-transitory storage medium, and a machine tool.
  • Patent Document 1 proposes a data collection device for transmitting data, and to transmit data on the cutting tool's condition collected by the sensor wirelessly to a data collection device.
  • Patent Document 1 The technology disclosed in Patent Document 1 allows each tool to communicate directly with the data collection device. There is no need for cables for the data collection device to collect sensor data, which is said to make machining easier.
  • the sensor abnormality determination device includes a determination unit that receives data from one or more sensors provided in a cutting tool via wireless communication and determines whether an abnormality has occurred in any of the one or more sensors based on the data, and a determination display unit that displays the determination result of the determination unit.
  • the present invention can be realized not only as a data collection device equipped with such a characteristic processing unit, but also as a sensor anomaly determination method having such characteristic processing steps, or as a program for causing a computer to execute such steps. It can also be realized as a semiconductor integrated circuit that realizes part or all of the sensor anomaly determination device, or as a sensor anomaly determination system that includes the sensor anomaly determination device.
  • FIG. 1 is a block diagram of a data collection system according to one embodiment of the present disclosure.
  • FIG. 2 is a block diagram of a cutting tool equipped with the data transmitter shown in FIG.
  • FIG. 3 is a block diagram showing the configuration of the data transmitter shown in FIG.
  • FIG. 4 is a block diagram showing a hardware configuration of the terminal shown in FIG.
  • FIG. 5 is a schematic diagram showing an example of a display on the monitor shown in FIG. 4 in a normal state.
  • FIG. 6 is a schematic diagram showing an example of a display on the monitor when an abnormality is found in a sensor.
  • FIG. 7 is a flowchart representing a control structure of a program executed by the terminal shown in FIG. FIG.
  • FIG. 8 is a flowchart showing a control structure of a program for implementing the sensor initialization process shown in FIG.
  • FIG. 9 is a flowchart showing a control structure of a program implementing the initial threshold setting process shown in FIG.
  • FIG. 10 is a flowchart showing a control structure of a program for implementing the sensor data acquiring process shown in FIG.
  • FIG. 11 is a flowchart showing a control structure of a program executed by a terminal according to the second embodiment of the present disclosure.
  • FIG. 12 is a flowchart showing a control structure of a program for implementing the abnormality determination and display process for each sensor shown in FIG.
  • FIG. 13 is a flowchart showing a control structure of a program executed by a terminal according to the third embodiment of this disclosure.
  • Patent Document 1 it is possible for a data collection device to monitor data collected by a sensor provided on the cutting tool regarding the operating state of the cutting tool.
  • the technology disclosed in Patent Document 1 is premised on the sensor operating normally. If an abnormality occurs in the sensor, the technology disclosed in Patent Document 1 has a problem in that erroneous information regarding the operating state of the cutting tool will be displayed.
  • the purpose of this disclosure is to provide a sensor abnormality determination device, a sensor abnormality determination system, a sensor abnormality determination method, a computer program, a non-transitory storage medium, and a machine tool that allow a user to easily know if there is an abnormality in a sensor when communication is performed between a data collection device and a cutting tool equipped with a sensor and a wireless communication device.
  • a sensor abnormality determination device includes a determination unit that receives data from one or more sensors provided in a cutting tool via wireless communication and determines whether an abnormality has occurred in any of the one or more sensors based on the data, and a determination display unit that displays the determination result of the determination unit.
  • the determination unit may include a sensor-specific determination unit that receives the data from each of the one or more sensors and determines whether or not an abnormality has occurred for each of the one or more sensors based on the data, and the determination display may display the result of the sensor-specific determination unit for each of the one or more sensors.
  • a data receiving unit may be further included that receives the data from the one or more sensors and displays the data for each sensor.
  • the data receiving unit may continue to receive the data from the one or more sensors and display the data for each sensor even after the determining unit has determined that an abnormality has occurred in any of the one or more sensors.
  • the determination unit and the data receiving unit may periodically receive the data from the one or more sensors for each first period and each second period, respectively. That is, the determination unit receives data from the one or more sensors for each first period and determines whether there is a sensor abnormality.
  • the data receiving unit receives and displays data from the one or more sensors for each second period.
  • the first period and the second period may be the same period.
  • the first period and the second period may be different from each other.
  • the period for determining a sensor abnormality and the period for displaying the data can be set to appropriate values, and the occurrence of a sensor abnormality and the display of the data can be performed at appropriate periods.
  • the cutting tool may have a function of detecting a specific abnormality of the sensor and transmitting an abnormality detection signal via wireless communication, and the judgment display unit may display a judgment result regarding the abnormality of the one or more sensors according to the judgment result of the judgment unit and the abnormality detection signal received from the cutting tool.
  • a sensor abnormality determination system is a sensor abnormality determination system including a cutting tool equipped with a sensor and an abnormality determination device that determines whether an abnormality has occurred in the sensor by wireless communication with the cutting tool, the cutting tool including a holder having a tip attachment portion, one or more sensors attached to the holder, and a data transmission unit provided within the holder that transmits data from the one or more sensors via wireless communication, the abnormality determination device including a determination unit that receives data from the one or more sensors via wireless communication and determines whether an abnormality has occurred in any of the one or more sensors based on the data, and a determination display unit that displays the determination result of the determination unit.
  • a sensor abnormality determination method includes a step in which a computer receives data from one or more sensors provided on a cutting tool via a wireless communication device and determines whether an abnormality has occurred in any of the one or more sensors based on the data, and a step in which the computer displays the determination result in the determining step on a display device.
  • a computer program causes a computer to function as a determination unit that receives data from one or more sensors provided in a cutting tool via wireless communication and determines whether an abnormality has occurred in any of the one or more sensors based on the data, and as a determination display unit that displays the determination result of the determination unit.
  • the computer can be made to function so that whether an abnormality has occurred in one or more sensors provided in a cutting tool can be visually determined through a display by the computer.
  • a non-transitory storage medium causes a computer to function as a determination unit that receives data from one or more sensors provided in a cutting tool via wireless communication and determines whether an abnormality has occurred in any of the one or more sensors based on the data, and as a determination display unit that displays the determination result of the determination unit.
  • a machine tool is a machine tool including a machining unit that performs machining using a cutting tool equipped with one or more sensors, and an abnormality determination unit that determines whether an abnormality has occurred in the sensor by wireless communication with the cutting tool, the abnormality determination unit including a determination unit that receives data from the one or more sensors through wireless communication and determines whether an abnormality has occurred in any of the one or more sensors based on the data, and a determination display unit that displays the determination result of the determination unit.
  • FIG. 1 shows a schematic configuration of a machining system 50 according to a first embodiment of this disclosure.
  • the machining system 50 includes a machining device 64 that performs machining on a workpiece using one or more cutting tools, each of which has one or more sensors and one or more cutting tools each of which has a data transmitter 54, a data transmitter 56, a data transmitter 58, etc., and a data collection system 52 that receives data from one or more sensors provided on each cutting tool via wireless communication from each of the data transmitters 54, 56, and 58, displays the time series of the data, and displays a sensor abnormality when a sensor abnormality is detected.
  • the data collection system 52 includes a wireless receiver 62 and a terminal 60 that has the function of receiving and analyzing data from the data transmitters 54, 56, and 58 via the wireless receiver 62 and displaying the data.
  • the terminal 60 further has the function of displaying the occurrence of a sensor abnormality if a sensor abnormality is detected.
  • FIG. 2 shows the configuration of a cutting tool 100 equipped with the data transmitter 54 of FIG. 1 as an example of a cutting tool used by the machining device 64.
  • the cutting tool 100 includes a holder 110 that detachably holds a cutting insert 112 for cutting at its tip.
  • the cutting tool 100 further includes a thermal sensor 114, a strain sensor 116, a strain sensor 118, and the like, which are installed in the holder 110.
  • the number and positions of these sensors are selected to be appropriate in light of the purpose.
  • the thermal sensor 114 is provided in a position close to the cutting insert 112.
  • the strain sensor 116 is provided on the upper surface of the holder 110.
  • the strain sensor 118 is provided on the front side surface of the holder 110.
  • a strain sensor (not shown) is provided on the side surface of the holder 110 opposite to the side surface on which the strain sensor 118 is provided.
  • sensors that are not shown will not be described.
  • Each sensor such as thermal sensor 114 , strain sensor 116 , and strain sensor 118 , is electrically connected to the data transmitter 54 , and the output of each sensor is transmitted to the data transmitter 54 .
  • FIG 3 is a block diagram showing the configuration of the data transmitter 54.
  • the data transmitter 54 includes a wireless communication unit 150, a CPU (Central Processing Unit) 152 connected to the wireless communication unit 150 and the thermal sensor 114, the strain sensor 116, and the strain sensor 118, a non-volatile memory 156 connected to the CPU 152, and a power supply 154 that supplies power to the wireless communication unit 150, the CPU 152, and the non-volatile memory 156.
  • a wireless communication unit 150 a CPU (Central Processing Unit) 152 connected to the wireless communication unit 150 and the thermal sensor 114, the strain sensor 116, and the strain sensor 118
  • a non-volatile memory 156 connected to the CPU 152
  • a power supply 154 that supplies power to the wireless communication unit 150, the CPU 152, and the non-volatile memory 156.
  • the non-volatile memory 156 stores the programs executed by the CPU 152.
  • the wireless communication unit 150 has a function of transmitting, under the control of the CPU 152, packets assembled from the sensor data received by the CPU 152 from the thermal sensor 114, the strain sensor 116, and the strain sensor 118 to the wireless receiver 62 shown in FIG. 1.
  • the power source 154 is a battery.
  • FIG. 4 is a hardware block diagram of the terminal 60 shown in FIG. 1.
  • this terminal 60 includes a computer 200, and a keyboard 206, a touchpad 204, and a monitor 202, all of which are connected to the computer 200, for interacting with a user.
  • a computer 200 and a keyboard 206, a touchpad 204, and a monitor 202, all of which are connected to the computer 200, for interacting with a user.
  • these are just one example of a configuration for when interaction with a user becomes necessary, and any general hardware and software that can be used for interacting with a user (e.g. a mouse, voice input, pointing devices in general) can be used.
  • computer 200 includes a CPU 220, a bus 228 connected to CPU 220, a ROM (Read-Only Memory) 222 connected to bus 228 and storing a boot-up program for computer 200, a RAM (Random Access Memory) 224 connected to bus 228 and storing instructions constituting a program at run time, a system program, a system state, working data, and the like, and an SSD (Solid State Drive) 226 which is a non-volatile memory connected to bus 228.
  • SSD 226 is a non-transient storage medium for storing programs executed by CPU 220 and data used by the programs executed by CPU 220.
  • the computer 200 further includes a display control unit 230, all of which are connected to the bus 228 and perform display using the monitor 202 under the control of the CPU 220, an input/output I/F (Interface) 232 to which peripheral devices are connected, a network I/F 236 that provides a connection to a network 210 that enables communication with other terminals, and a USB port 234 to which a USB (Universal Serial Bus) memory 208 can be attached/detached and that provides communication between the USB memory 208 and each unit within the computer 200.
  • a display control unit 230 all of which are connected to the bus 228 and perform display using the monitor 202 under the control of the CPU 220
  • an input/output I/F (Interface) 232 to which peripheral devices are connected
  • a network I/F 236 that provides a connection to a network 210 that enables communication with other terminals
  • a USB port 234 to which a USB (Universal Serial Bus) memory 208 can be attached/detached and that
  • the programs and the like for implementing the terminal 60 according to this embodiment are stored, for example, in the SSD 226, RAM 224, or USB memory 208 shown in FIG. 4, or in a storage medium of an external device (not shown) connected to the bus 228 via the network I/F 236 and the network 210.
  • these data and parameters are written, for example, from outside to the SSD 226 and loaded into the RAM 224 when executed by the computer 200.
  • the program for implementing the terminal 60 according to this embodiment is stored, for example, in the USB memory 208, and when the USB memory 208 is inserted into the USB port 234, the program is transferred to and stored in the SSD 226.
  • the program may be sent to the computer 200 via the network 210 and the network I/F 236 and stored in the SSD 226.
  • the program is loaded into RAM 224 when it is executed.
  • the source program may be input using keyboard 206, monitor 202, and touchpad 204, and the compiled object program may be stored in SSD 226.
  • a script input using keyboard 206 or the like may be stored in SSD 226.
  • a program that functions as a virtual machine must be installed in computer 200 in advance.
  • CPU 220 reads a program from RAM 224 according to an address indicated by an internal register called a program counter (not shown), interprets the instructions, and reads data required to execute the instructions from RAM 224, SSD 226 or other devices according to the address specified by the instruction, and executes the process specified by the instruction.
  • CPU 220 stores the execution result data at an address specified by the program, such as RAM 224, SSD 226, or a register in CPU 220. At this time, the program counter value is also updated by the program.
  • Computer programs may be loaded directly into RAM 224 from USB memory 208, or via network 210 and network I/F 236.
  • a program that realizes the functions of each part according to the above-mentioned embodiment in cooperation with the computer 200 includes a plurality of instructions written and arranged to operate the computer 200 to realize those functions. Some of the basic functions required to execute the instructions are provided by the operating system (OS (Operating System)) that runs on the computer 200, or a third-party program, or by modules of various tool kits installed on the computer 200. Thus, the program does not necessarily include all of the functions required to realize the system and method of this embodiment.
  • the program need only include instructions that perform the operations of each of the above-mentioned devices and their components by statically linking appropriate functions or functions of a "programming tool kit" in a controlled manner to obtain the desired results, or by dynamically linking to those functions when the program is executed.
  • the method of operating the computer 200 for this purpose is well known, so it will not be repeated here.
  • FIG. 5 shows an example of the display on the monitor 202 of the terminal 60 when the sensors of the cutting tool 100 and the like used by the machining device 64 are operating normally.
  • the normal screen 250 at this time includes a sensor status display area 260 and a sensor data display area 262.
  • the sensor status display area 260 includes a status display section 268, a status display section 270, a status display section 272, and a status display section 274 that display the sensor status for each sensor equipped on the cutting tool used by the machining device 64.
  • FIG. 5 is an example of the display, and the number of status display sections increases or decreases depending on the number of sensors being used.
  • the sensor status display area 260 further includes a measurement start button 264 that the user uses to instruct the terminal 60 to measure data using each sensor, and a measurement stop button 266 that the user uses to stop the measurement.
  • the sensor data display area 262 data from each sensor displayed in the sensor status display area 260 is displayed in a predetermined format.
  • the time series of output from the sensors corresponding to status display unit 268, status display unit 270, status display unit 272, and status display unit 274, respectively, are displayed as time series graph 276, time series graph 278, time series graph 280, and time series graph 282.
  • the status display unit in the sensor status display area 260 may be scrolled. In that case, it is desirable to scroll the graphs of each sensor data in the sensor data display area 262 in sync with the scrolling of the sensor status display area 260.
  • FIG. 6 shows a display 300 on the monitor 202 as an example of when some abnormality is detected in the sensor in this embodiment.
  • Display 300 differs from normal screen 250 in FIG. 5 in that the display in status display section 274 is different from that in normal screen 250. That is, in normal screen 250 in FIG. 5, a check mark is displayed in status display section 274, and the background is displayed in the normal background color (e.g., green).
  • status display section 274 instead of a check mark, displays a cross mark indicating the occurrence of an abnormality, and the background color is not the normal green but a warning color for when an abnormality occurs (e.g., red). Note that in this embodiment, even when it is determined that an abnormality has occurred, the sensor data received by terminal 60 is displayed as is in the time series graph 282.
  • Program Configuration Fig. 7 shows the overall control configuration of the program executed by terminal 60. Referring to Fig. 7, this program 350 starts operation when the measurement start button is pressed, and includes step 360 of performing a sensor initialization process for each sensor from which data is being collected, and step 362 of performing a process of setting an initial threshold value for each sensor to determine whether or not there is an abnormality.
  • the program 350 further includes step 364 for executing a sensor data acquisition process for acquiring sensor data from each sensor, and step 366 for branching the flow of control according to whether or not the measurement stop button 266 shown in FIG. 5 has been pressed after completion of step 364.
  • step 366 for branching the flow of control according to whether or not the measurement stop button 266 shown in FIG. 5 has been pressed after completion of step 364.
  • such a time interval of repetition is called a "period.”
  • the acquisition of sensor data, the determination of a sensor abnormality using the sensor data, and the display update of the sensor data are all executed within one repetition. That is, the acquisition of sensor data, the determination of a sensor abnormality, and the display update of the sensor data are repeated with the same period. It should be noted that it may be desirable to process data with a stricter period. In that case, although not shown in FIG.
  • a step may be provided in the path returning control from step 366 to step 364 to measure the execution time of the repetition and set a waiting time to adjust the repetition period to a constant value so that the time from when execution of step 364 is started to when execution of step 364 is started again is equal to the above-mentioned specific period.
  • FIG. 8 shows the details of step 360 in FIG. 7.
  • step 360 includes step 400 of substituting 1 for variable n, which indicates the number of sensors, and step 402 of performing initialization processing on the nth sensor indicated by variable n.
  • terminal 60 inquires as to whether or not there is an obvious abnormality with the target sensor.
  • data transmitter 54 shown in FIG. 2 determines, for example, whether there is a break in the connection line with the sensor, whether the sensor is submerged in water, etc., and if there is an abnormality, transmits a corresponding error code to terminal 60 via wireless receiver 62. If there is no abnormality in the sensor, data transmitter 54 transmits a code indicating a normal state to terminal 60.
  • Step 360 further includes step 404, which branches the control flow depending on whether or not the response received from the target sensor in step 402 includes an error code, and step 406, which, when the determination in step 404 is positive, i.e., when the response received from the target sensor includes an error code, sets a flag indicating an abnormality in the sensor, for example, and stores the error code, assuming that an abnormality has occurred.
  • step 406 the status display unit of the target sensor displays an error. When there is no error, the status display unit of the target sensor displays normal.
  • Step 360 further includes step 408, which adds 1 to variable n when the determination in step 404 is negative, and after the determination in step 404 is positive and the processing in step 406 is completed, and step 410, which branches the control flow according to whether the value of variable n is greater than the total number N of target sensors. If the determination in step 410 is negative, control returns to step 402, and the processing in steps 402 to 408 is repeated for the sensor represented by the updated value of variable n. If the determination in step 410 is positive, execution of step 360 is completed, and control proceeds to step 362 in FIG. 7.
  • step 362 includes step 450 of substituting 1 into a variable t indicating the time order of data in the time series, step 452 of substituting 1 into a variable n indicating a sensor to be processed, and step 454 of acquiring an initial strain ⁇ n1 and an initial temperature T n1 from each sensor at the n-th sensor.
  • Step 362 further includes step 456 for branching the flow of control according to whether the initial strain ⁇ n1 obtained in step 454 is within a range of a predetermined threshold value ⁇ THI , and step 458 for determining that the n-th sensor is abnormal and setting an abnormality flag provided for that sensor in response to a negative determination in step 456.
  • step 458 the status indicator of the target sensor is set to indicate abnormality, as shown in Fig. 6. When the determination in step 456 is positive, the status indicator of the target sensor is set to indicate normality.
  • Step 362 further includes step 460 for setting an initial threshold value for the nth sensor based on the initial strain when the determination in step 456 is positive, and when the determination in step 456 is negative and the processing of step 458 is completed, step 462 for adding 1 to variable n, and step 464 for branching the flow of control depending on whether the value of variable n is smaller than the total number N of sensors.
  • step 464 When the determination in step 464 is negative, control returns to step 450 and the subsequent processing is repeated.
  • the determination in step 464 is positive, the execution of step 362 is completed and control proceeds to step 364 in FIG. 7.
  • Fig. 10 shows a control structure of the program executed in step 364.
  • step 364 includes step 500 of substituting 1 for variable n and variable t+1 for variable t, and step 502 of acquiring sensor data from the n-th sensor and displaying it in sensor data display area 262 of Fig. 5.
  • the data from the strain sensor acquired in step 502 is sensor data ⁇ nt
  • the data from the temperature sensor is sensor data Tnt .
  • This program further includes step 504 of calculating the amount of correction of the thermal strain value using a thermal drift correction function TD( Tnt , Tn1 ) of the strain sensor, step 506 of calculating a threshold value ⁇ THnt for judging an abnormality of the strain value at temperature Tnt , and step 508 of branching the control flow according to whether the sensor data ⁇ nt is within the range of the threshold value ⁇ THnt .
  • the thermal drift correction function TD( Tnt , Tn1 ) is a correction function determined for each sensor from the sensor data Tn1 when the value of the variable t is 1 and the current sensor data Tnt . This correction function is determined in advance by experiments.
  • Step 364 further includes step 510, which determines that an abnormality has occurred in the nth sensor when the determination in step 508 is negative, and sets an abnormality flag corresponding to the nth sensor; step 511, which displays an error or normal state on the status display unit (see FIG. 6) of the target sensor depending on whether the abnormality flag is set or not when the determination in step 508 is positive, and when the determination in step 508 is negative and the processing in step 510 is completed, and which updates the display of the sensor output on the screen using the acquired sensor data; and step 512, which adds 1 to the value of variable n and assigns the result to variable n.
  • Step 364 further includes, following step 512, step 514, which branches the flow of control depending on whether the value of variable n is greater than the total number of sensors N. If the determination in step 514 is negative, control returns to step 504. If the determination in step 514 is positive, execution of step 364 ends and control returns to step 366 in FIG. 7.
  • the machining system 50 operates as follows: Various cutting tools each equipped with a data transmitter are attached to the machining device 64, and machining of the workpiece is started.
  • the normal screen 250 shown in Fig. 5 is displayed on the monitor 202.
  • this program starts, communication is performed with each sensor, and a screen such as that shown in Fig. 5 is displayed according to the results of that communication.
  • the normal/abnormal display of the status display for each sensor is not performed until the measurement start button 264 is operated. Furthermore, no data is displayed in the sensor data display area 262.
  • step 360 As shown in FIG. 8, 1 is assigned to the variable n representing the number of sensors (step 400).
  • Initialization processing is performed on the first sensor (step 402).
  • the terminal 60 inquires as to whether or not there is an obvious abnormality with the target sensor.
  • the data transmitter 54 shown in FIG. 2 determines whether or not there is an abnormality in each sensor, and if there is an abnormality, transmits information identifying the sensor and an error code indicating the abnormality to the terminal 60 via the wireless receiver 62. If there is no abnormality in the sensor, the data transmitter 54 transmits a code indicating a normal state to the terminal 60.
  • the terminal 60 branches the control flow according to whether or not an error code is included in the response received from the data transmitter for the target sensor (step 404).
  • the terminal 60 sets a flag indicating an abnormality in that sensor and stores the error code (step 406).
  • the terminal 60 also displays an abnormality on the status display unit of the target sensor.
  • the terminal 60 further adds 1 to the variable n (step 408) when the determination in step 404 is negative, and after the determination in step 404 is positive and the processing in step 406 is completed. As a result, the value of the variable n becomes 2.
  • the determination in step 410 becomes positive, and control proceeds to step 362 in FIG. 7 (details in FIG. 9).
  • step 362 the terminal 60 assigns 1 to a variable t indicating the time order of the data in the time series (step 450).
  • the terminal 60 further assigns 1 to a variable n indicating the sensor to be processed (step 452).
  • the terminal 60 acquires an initial strain ⁇ n1 and an initial temperature T n1 from the first sensor at the nth (first) sensor (step 454).
  • the terminal 60 further branches the flow of control according to whether the initial strain ⁇ n1 obtained in step 454 is within the range of a predetermined threshold ⁇ THI (step 456). If the determination in this step is negative, the terminal 60 determines that the sensor (the first sensor) is abnormal, and sets an abnormality flag provided for that sensor (step 458). At this time, the terminal 60 displays an abnormality on the status display unit of the target sensor.
  • the terminal 60 sets an initial threshold value for the first sensor based on the initial strain of the first sensor (step 460).
  • the terminal 60 adds 1 to the variable n (step 462).
  • the value of the variable n becomes 2.
  • the terminal 60 branches the flow of control according to whether the value of the variable n (i.e., 2) is smaller than the total number N of sensors (step 464).
  • the determination in step 464 becomes negative, and control returns to step 450. Thereafter, the above process is repeated with the value of the variable n set to 2.
  • the determination in step 464 becomes positive, the execution of step 362 is completed, and control proceeds to step 364 in FIG. 7 (details in FIG. 10).
  • the terminal 60 assigns 1 to the variable n and assigns the variable t+1 to the variable t (step 500). As a result, the value of the variable t becomes 2 when step 500 is executed for the first time.
  • the terminal 60 further acquires sensor data from the first sensor and displays it on the monitor 202 in FIG. 5 (step 502).
  • the data from the strain sensor acquired in step 502 is the strain value ⁇ 1,2 and the temperature T 1,2 .
  • the terminal 60 also calculates a threshold value ⁇ THnt for determining an abnormality of the strain value at temperature T1,2 (step 506).
  • the terminal 60 further branches the flow of control according to whether the sensor data ⁇ 1,2 is within the range of the threshold value ⁇ TH1,2 or not (step 508).
  • step 508 determines that an abnormality has occurred in the first sensor, and sets an abnormality flag corresponding to the first sensor (step 510). In this case, as shown in FIG. 6, the terminal 60 changes the display in the status display section corresponding to the target sensor to an abnormal display, and also updates the display using the sensor data (step 511). Thereafter, the terminal 60 advances control to step 512. If the determination in step 508 is negative, the terminal 60 changes the measurement start button in the sensor status display area 260 of the target sensor to a normal display, updates the display using the sensor data (step 511), and advances control to step 512.
  • step 512 1 is added to the value of variable n and assigned to variable n (step 512). As a result, the value of variable n becomes 2.
  • step 364 is periodically repeated until the measurement stop button 266 shown in FIG. 5 is pressed.
  • the normality or abnormality of each sensor is displayed in the sensor status display area 260 by the measurement start button.
  • the sensor data display area 262 displays a time series of data acquired from the sensor. This display continues without interruption even if an error is found in the sensor.
  • Second embodiment A Configuration
  • the processing for all sensors is performed sequentially.
  • this disclosure is not limited to such an embodiment.
  • the processing for each sensor can also be performed in parallel.
  • the processing for each sensor is performed in parallel in this manner.
  • the hardware used in this second embodiment is basically the same as that in the first embodiment shown in Figures 1 to 4.
  • the processing executed by the data transmitter 54 in this second embodiment is also the same as in the first embodiment.
  • the display contents shown in Figures 5 and 6 are also the same in the second embodiment and the first embodiment. The difference is in the program executed by the terminal 60.
  • step 560 which generates and starts thread instances for acquiring sensor data, the number of which matches the number of sensors (four in this embodiment), and steps 562, 564, 566, and 568, which execute processes for each sensor in parallel in each thread started in step 560.
  • steps 562, 564, 566, and 568 are executed by different threads, so they may be considered to be executed independently of each other.
  • the program 550 also ends.
  • FIG. 12 shows the control structure of the program executed, for example, in step 562.
  • the programs executed in the other steps 564, 566, and 568 have the same control structure.
  • the program executed in step 562 is the same as the program in the first embodiment whose control structure is shown in FIGS. 7 to 10, in which the number of sensors n is fixed at 1.
  • step 562 includes step 600 for performing initialization processing such as initialization of a storage area and connection to a target sensor, step 601 for branching the flow of control according to whether or not an error code is included in the response received from the sensor in step 600, and step 602 for setting an abnormality flag for the sensor when the determination in step 601 is affirmative.
  • Step 562 further includes step 603 for substituting an initial value of 1 into a variable t indicating the chronological order of measurement, step 604 for acquiring an initial strain ⁇ a1 and an initial temperature T a1 as sensor data from the sensor targeted by this thread, step 602 for branching the flow of control according to whether or not an error code is included in the sensor data acquired in step 600, and step 604 for determining that an abnormality has occurred in the target sensor when the determination in step 602 is affirmative, setting an abnormality flag, and changing the display of a status display unit (see FIGS. 5 and 6) for the target sensor to an abnormality display (see status display unit 274 in FIG. 6).
  • Step 562 further includes step 603 of substituting an initial value of 1 into a variable t indicating the time order of measurement when the determination in step 602 is negative, and when the determination in step 602 is positive and step 604 is completed; step 604 of acquiring an initial strain ⁇ a1 and an initial temperature T a1 from the sensor targeted by this thread; step 606 of branching the flow of control according to whether the initial strain ⁇ a1 is within the range of the threshold value ⁇ THI ; step 608 of setting an abnormality flag indicating that there is an abnormality in the strain sensor when the determination in step 606 is positive, and when the determination in step 606 is negative and step 608 is completed, step 610 of setting an initial threshold value ⁇ aTHI based on the initial strain ⁇ a1 .
  • Step 562 further includes, following step 610, step 611 of adding 1 to variable t, step 612 of acquiring sensor data, that is, strain value ⁇ at and temperature T at , from the target sensor, step 614 of calculating the amount of fluctuation in the strain value due to heat using a thermal drift correction function TD(T at , T a1 ) of the strain sensor, and step 616 of calculating a threshold value ⁇ THt at temperature T at using the following formula:
  • Step 562 further includes step 618 for branching the flow of control according to whether or not the strain value ⁇ at acquired in step 612 is within the range of the threshold value ⁇ THt calculated in step 616, and step 620 for determining that an abnormality has occurred in the target sensor and setting an abnormality flag when the determination in step 618 is negative.
  • Step 562 further includes step 621 for changing the status display section corresponding to the target sensor to an abnormality display (see FIG.
  • step 622 for branching the flow of control according to whether or not the measurement stop button 266 shown in FIG. 5 has been pressed. If the determination in step 622 is negative, control proceeds to step 612. As a result, 1 is added to the value of the variable t, and the processes of steps 611, 612, 614, 616, 618, 620, 621, and 622 are repeated. If the determination in step 622 is positive, the execution of step 662 ends. That is, the execution of this thread is completed.
  • the screen shown in FIG. 5 is displayed on the monitor 202 of the terminal 60.
  • the CPU 220 starts executing a program 550 whose control structure is shown in FIG. 11.
  • the CPU 220 generates and starts thread instances for acquiring sensor data, the number of which matches the number of sensors (four in this embodiment) (step 560).
  • the CPU 220 executes processing for each sensor in parallel in each started thread (steps 562, 564, 566, and 568). These steps 562, 564, 566, and 568 are executed in parallel by different threads.
  • step 562 after the initialization process (step 600), the CPU 220 judges whether or not there is an error code in the response received from the sensor targeted by this thread (step 601). If there is an error code, an abnormality flag is set (step 602).
  • step 603, 1 is substituted for the variable t (step 603), and the initial strain ⁇ a0 and the initial temperature T a0 are acquired as sensor data from the targeted sensor (step 604).
  • the CPU 220 further branches the flow of control according to whether or not the initial strain ⁇ a1 is within the range of the threshold value ⁇ THI (step 606).
  • the CPU 220 sets an abnormality flag as an abnormality in the strain sensor (step 608).
  • the CPU 220 sets the initial threshold value ⁇ aTHI based on the initial strain ⁇ a1 (step 610).
  • the CPU 220 further adds 1 to the variable t (step 611) and acquires the strain value ⁇ at and the initial temperature T at (t indicates the time order of the data) which are sensor data from the sensor (step 612).
  • the CPU 220 calculates the amount of change in the strain value due to heat using the thermal drift correction function TD(T at , T a1 ) of the strain sensor (step 614).
  • the CPU 220 calculates the threshold value ⁇ THt at the temperature T at using the above-mentioned formula (step 616).
  • the CPU 220 further branches the flow of control according to whether the strain value ⁇ at acquired in step 612 is within the range of the threshold value ⁇ THt calculated in step 616 (step 618).
  • the CPU 220 determines that an abnormality has occurred in the target sensor, and sets an abnormality flag (step 620).
  • the CPU 220 causes the status display section corresponding to the target sensor to display an abnormality (see FIG. 6).
  • the CPU 220 then branches the flow of control according to whether the measurement stop button 266 shown in FIG. 5 has been pressed (step 622).
  • the CPU 220 returns control to step 612, adds 1 to the value of the variable t (step 611), and repeats the processes of steps 612, 614, 616, 618, 620, 621, and 622. If the measurement stop button 266 has been pressed, the CPU 220 ends the execution of this thread.
  • step 660 which starts a thread that executes error monitoring process 662
  • step 664 which starts threads such as processes 666, 668, 670 and 672 for acquiring and displaying the output of each sensor, the number of which is equal to the number of sensors to be monitored.
  • measurement stop button 266 shown in FIG. 5 is pressed, all of these threads are terminated and execution of program 650 is also terminated.
  • step 662 has a configuration basically similar to that of the program in FIG. 7.
  • step 511 of step 364 shown in FIG. 10 data is not displayed, and only the process of updating the status display section corresponding to the target sensor based on the abnormality flag is executed. In other words, by repeatedly executing step 364 (see FIG. 7), the process of sequentially determining abnormalities for multiple sensors is repeated.
  • step 666 shown in FIG. 13 has a structure that basically extracts only steps 600, 603, 604, 611, 612, 621, and 622 from step 562 shown in FIG. 12.
  • step 621 only the display of the sensor data is updated based on the sensor data.
  • a wait time can be provided at the end of each processing unit so that the repeated processing in each program is executed at a predetermined cycle.
  • sensor anomaly determination is achieved by repeating the process of checking multiple sensors in order. Meanwhile, the data display based on the output of each sensor is updated according to the repetition period of the process for each sensor. In other words, the execution period for sensor anomaly determination and the display period for the sensor output are independent of each other, and appropriate periods can be set for each application.
  • the wireless receiver 62 and the terminal 60 have a one-to-one relationship.
  • this disclosure is not limited to such embodiments.
  • a plurality of terminals 60 may be connected to one wireless receiver 62 via a network, and each terminal 60 may collect a plurality of sensor data and display errors.
  • the terminal that acquires the sensor data and checks for errors may be separate from the terminal that displays the data as shown in FIG. 5 and FIG. 6.
  • the sensors provided in the cutting tool 100 are a heat sensor and a strain sensor.
  • An acceleration sensor may also be provided as a sensor.
  • Each process (each function) in the above-mentioned embodiments is realized by a processing circuit (circuitry) including one or more processors.
  • the processing circuit may be composed of an integrated circuit that combines one or more memories, various analog circuits, and various digital circuits in addition to the one or more processors.
  • the one or more memories store programs (instructions) that cause the one or more processors to execute each of the above processes.
  • the one or more processors may execute each of the above processes according to the program read from the one or more memories, or may execute each of the above processes according to a logic circuit designed in advance to execute each of the above processes.
  • the processor may be any of various processors suitable for computer control, such as a CPU, a GPU (Graphics Processing Unit), a DSP (Digital Signal Processor), an FPGA (Field-Programmable Gate Array), or an ASIC (Application Specific Integrated Circuit).
  • the physically separated processors may cooperate with each other to execute the above processes.
  • the processors mounted on each of the physically separated computers may cooperate with each other via a network such as a LAN (Local Area Network), a WAN (Wide Area Network), or the Internet to execute the above processes.
  • the program may be installed in the memory from an external server device or the like via the network, or may be distributed in a state stored in a recording medium such as a CD-ROM (Compact Disc Read-Only Memory), a DVD-ROM (Digital Versatile Disc Read-Only Memory), or a semiconductor memory, and then installed in the memory from the recording medium.
  • a recording medium such as a CD-ROM (Compact Disc Read-Only Memory), a DVD-ROM (Digital Versatile Disc Read-Only Memory), or a semiconductor memory, and then installed in the memory from the recording medium.

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  • Physics & Mathematics (AREA)
  • General Physics & Mathematics (AREA)
  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Computer Networks & Wireless Communication (AREA)
  • Arrangements For Transmission Of Measured Signals (AREA)
  • Testing Or Calibration Of Command Recording Devices (AREA)
  • Machine Tool Sensing Apparatuses (AREA)
PCT/JP2022/040942 2022-11-02 2022-11-02 センサ異常判定装置、センサ異常判定システム、センサ異常判定方法、コンピュータプログラム、非一時的記憶媒体、および工作機械 Ceased WO2024095382A1 (ja)

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JP2023524657A JP7405307B1 (ja) 2022-11-02 2022-11-02 センサ異常判定装置、センサ異常判定システム、センサ異常判定方法、コンピュータプログラム、非一時的記憶媒体、および工作機械

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