Machine tool, production management system and method for estimating and detecting tool life

Abstract

To efficiently estimate and detect a tool life of a machine tool while lowering an occupation ratio in a data band of a communication line between a machine tool and an upper-level controller, a management apparatus or the like. A machine tool to be managed by a production management apparatus includes a motor for moving one of a workpiece to be machined and a tool for performing a machining operation, an amplifier for driving the motor, a servo controller for controlling the motor via the amplifier based on a notification of a predetermined machining operation, and an NC device for notifying the servo controller of the predetermined machining operation. The servo controller obtains servo data representing a load on the amplifier, performs a first processing for compressing the servo data, and transmits the compressed data to the NC device.

Claims

1. A production management system comprising: a machine tool; and a production management apparatus for managing the machine tool, wherein the machine tool comprises: a motor for moving one of a workpiece to be machined and a tool for performing a machining operation; an amplifier for driving the motor; a servo controller for controlling the motor via the amplifier based on a notification of a predetermined machining operation; and a numerical controlling (NC) device for notifying the servo controller of the predetermined machining operation, wherein the servo controller obtains servo data representing a load on the amplifier at high speed through high-speed communication, performs a first processing for compressing the servo data, and transmits the compressed servo data subjected to the first processing to the NC device through medium-speed communication, the NC device performs a second processing for compressing the received compressed servo data, and transmits the compressed data subjected to the second processing to the production management apparatus through low-speed communication, the production management apparatus stores the transmitted data in a predetermined memory, monitors a change in the stored data, and performs at least one of estimation and detection of a tool life based on a predetermined determination criterion, after performing the second processing, the NC device adds machining conditions to the compressed data subjected to the second processing, and the production management apparatus stores the transmitted data for each of the machining conditions.

2. The production management system according to claim 1, wherein the NC device performs a squaring and integrating processing to the data as the second processing for compressing the received compressed servo data.

3. The production management system according to claim 1, wherein the servo controller performs a squaring and integrating processing to the servo data at a predetermined time as the first processing for compressing the servo data.

4. The production management system according to claim 1, wherein the servo data is a current value of the motor, and the current value represents torque of the motor.

5. The production management system according to claim 1, wherein the production management apparatus monitors a change in the data stored for each machining condition, and issues a warning to a user when values of consecutive n pieces of the data exceed a predetermined first threshold value, wherein the n is a natural number.

6. The production management system according to claim 1, wherein the production management apparatus monitors a change in the data stored for each machining condition, and issues a warning to a predetermined upper-level management apparatus or management section when values of consecutive m pieces of the data exceed a predetermined second threshold value, wherein the m is a natural number.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is an overall configuration diagram of a production management system according to the present embodiment.

(2) FIG. 2 is an overall explanatory diagram illustrating a configuration of an overall production system according to the present embodiment.

(3) FIG. 3 is an example of torque monitoring in the case of a tool in a normal state.

(4) FIG. 4 is an example of torque monitoring in the case of a tool in a state just before breaking due to wear.

DETAILED DESCRIPTION OF THE INVENTION

(5) One preferable embodiment according to the present invention is described below with reference to the drawings.

(6) 1. Principle

(7) In the present embodiment, a tool life is generally estimated by the process as below. First, a square integration value of values of torque at a normal operation is stored as an initial value. Next, the state of machining is grasped by automatically measuring vibration during machining. Then, a tool life is estimated from the grasped machining state. A tool life is estimated through such a process in order to suppress defective parts from being produced. In particular, in the present embodiment, a value of torque (current value) is compressed through squaring and integrating. Accordingly, the method enables to reduce the amount of data as compared with the method of transmitting a value of torque without any change to an upper-level controller and management apparatus.

(8) 2. Configurations of Production Management Apparatus and Machine Tool According to Present Embodiment

(9) FIG. 1 is an overall configuration diagram of a production management system 10 including a production management apparatus 100 according to the present embodiment and a machine tool 200 managed by the production management apparatus 100. Although only one unit of the machine tool 200 is illustrated in the production management system 10 shown in FIG. 1, a plurality of the machine tools 200 may be connected to the production management apparatus 100. As shown in FIG. 1, the machine tool 200 in FIG. 1 includes an NC device 202, a servo controller 204, an amplifier 206, a motor 208, and a detector 210 for detecting a rotation of the motor.

(10) As shown in FIG. 1, the production management apparatus 100 manages the machine tool 200. In other words, the production management apparatus 100 monitors and manages the operation of the machine tool 200. Specifically, the production management apparatus 100 monitors the operation of the machine tool by receiving a feedback signal from the machine tool 200, and thereby issues a warning to the machine tool 200, gives an instruction for stop or performs other operation based on the operation of the machine tool. It is noted that the feedback signal is generally transmitted through low-speed communication.

(11) The NC device 202 notifies, using a program or a signal, the servo controller 204 to perform a specific machining operation, that is, to perform specific machining with a specific tool. The notification is performed through medium-speed communication inside the machine tool 200. The medium-speed communication refers to communication having communication speed not lower than the above low-speed communication, which is communication having communication speed at least equal to or faster than the above low-speed communication.

(12) Based on the notification from the NC device 202, the servo controller 204 issues a voltage command to the amplifier 206 to drive the motor 208. At this time, the servo controller 204 receives a feedback signal of current from the amplifier 206. The servo controller 204 further receives a feedback signal of the position and speed of the motor 208 output by the detector 210 attached to the motor 208, and performs a so-called feedback control by controlling the motor 208 to adjust the position and speed according to the notification described above.

(13) The servo controller 204 samples the feedback signals of current value at the timing of receiving the notification from the NC device 202, so as to obtain data A. Since the current value of the motor 208 represents the torque of the motor, it can be said that the data A correspond to the servo data representing the torque. The operation to obtain the data A corresponds to a preferable example of the step of torque obtaining in the scope of the claims. The servo controller 204 further processes the data A (first processing) to obtain data B, and transfers (feeds back) the data B to the NC device 202 (refer to FIG. 1).

(14) Servo Data

(15) The current value of the motor 208 corresponds to a preferable example of the servo data in the scope of the claims. Although the current value is described as an example of the servo data in the present embodiment, other servo data may be used as long as the parameter thereof express torque or a load of the motor 208.

(16) First Processing

(17) The processing to the data A refers to, for example, a squaring and integrating processing or the like. The processing to the data A corresponds to a preferable example of the first processing in the scope of claims, and corresponds to one type of compression processing. In the present embodiment, although the squaring and integrating processing is described as one example of the compression processing, other compression processing may be used. Further, the processing to the data A corresponds to a preferable example of the step of first compressing in the scope of claims. In order to perform more precise estimation and detection, sampling at high speed is preferable.

(18) The voltage command from the servo controller 204 to the amplifier 206 is transmitted through high-speed communication. The high-speed signal may be transmitted as an analog signal which transmits a voltage without any change, or may be transmitted as a digital signal. In either case, the high-speed communication refers to the communication where a signal transmission speed is faster than the above medium-speed communication. The feedback signal of current received from the amplifier 206 is also transmitted through similar high-speed communication (refer to FIG. 1). On the other hand, transferring (feedback) from the servo controller 204 to the NC device 202 is performed through medium-speed communication.

(19) The amplifier 206 power-amplifies the voltage command (voltage signal) output by the servo controller 204 so as to drive the motor 208. The current value in the case of actually driving the motor 208 is transmitted to the servo controller 204. Such transmission is performed through high-speed communication. A circuit in which the voltage representing the current value is fed back is available. The current value may be converted into a digital signal by a sensor so as to be transmitted by an optical fiber or the like. In order that the motor 208 is controlled promptly, the current value is transmitted at high speed, which is referred to as high speed communication.

(20) The motor 208 is driven by the amplifier 206 to move a workpiece and a tool. In other words, the motor 208 serves as the motor 208 to move one of a workpiece to be machined and a tool for performing a machining operation, which corresponds to a preferable example of the motor in the scope of claims.

(21) The NC device 202 processes the data B (second processing: squaring and integrating processing or the like) transferred (fed back) through medium-speed communication before the previous notification is completed, and adds machining conditions (tool and machining) to the performed machining operation to construct data C. The NC device 202 stores the data C in a memory of the NC device 202. The memory of the NC device 202 may be a so-called built-in memory, or may be a memory disposed externally. The processing of storing the data C obtained after being compressed by the NC device 202 in the memory corresponds to a preferable example of the storing step in the scope of claims.

(22) Second Processing

(23) A characteristic feature in the present embodiment is that the NC device performs the second processing. Thereby, the amount of data is enabled to be further reduced. The second processing corresponds to a preferable example of the second processing in the scope of claims, and is one type of compression operation. Herein, other type of compression operation may serve as the second processing of the squaring and integrating processing. The second processing corresponds to a preferable example of the second compressing step in the scope of claims. The NC device 202 monitors a change in the data C according to the above machining conditions in the data C by referring to the above memory, and estimates and/or detects a tool life according to predetermined determination conditions. The processing of estimating and/or detecting a tool life corresponds to a preferable example of the estimating and detecting step in the scope of claims.

(24) Estimation and Detection

(25) The estimation in the present specification refers to estimating of a future tool life, and the detection refers to detection of whether or not the tool has reached its end of life. In the case of a tool having reached its end of life, in general, the tool is subjected to replacement. In the case where a tool is determined to closely reach its end of life as a result of estimating the tool life, a tool for replacement may be prepared (may be ordered for preparation).

(26) The NC device 202 notifies (performs transmission to), through low-speed communication, the upper-level production management apparatus 100 of the above data C to which the machining conditions are attached. The notification is performed through low-speed communication. That is, the communication between the machine tool 200 and the production management apparatus 100 is performed through low-speed communication.

(27) The production management apparatus 100 stores the data C obtained through notification (fed back) in the storage of the production management apparatus 100. The storage shall preferably have a large capacity. The production management apparatus 100 estimates or detects a tool life in accordance with a change in the data C according to the machining conditions based on a predetermined determination conditions. Then, based on the estimation result and the detection result, the production management apparatus 100 may issue a warning to a user, or may notify the NC device to stop the operation of the machine tool 200 or other operation.

(28) Determination Conditions

(29) The production management apparatus 100 monitors a change in the data C for each machining condition having been transmitted (stored), and issues a warning to a user in the case where the values of consecutive n pieces of the data C exceed a predetermined first threshold value. The above-described n is a natural number. Although a warning is issued to a user in the present specification, a warning may be issued to any of various management sections, management apparatuses, and machine tools. The production management apparatus 100 further monitors a change in the data C for each machining condition having been transmitted (stored), and issues a warning to a predetermined upper-level management apparatus or management section in the case where the values of consecutive m pieces of the data exceed a predetermined second threshold value. The above-described m is a natural number. The both n and m may be any of natural numbers, and any threshold values may be adopted as the first threshold value and the second threshold value.

(30) In the present embodiment, the processing in two steps (two types of processing) is described above. Any number of such determination criteria may be prepared. It is preferable that n, m, the first threshold value, and the second threshold value are set in advance, but they may be dynamically changed. In the present embodiment, the production management apparatus 100 performs warring and stopping. Alternatively, the NC device 202 of the machine tool may perform the above-described operations of the production management apparatus 100 to estimate and detect the tool life. Similarly, the NC device 202 may issue a warning or the like based on such estimation result and detection result. The operation may be performed based on determination criteria by use of n, m, the first threshold value, and the second threshold value, as described above.

(31) In the present embodiment, the production management apparatus 100 performs warning or stopping. Alternatively, the production management apparatus 100 may transmit such estimation result and detection result to an upper-level advanced production management apparatus, and the upper-level advanced production management apparatus may perform warning or the like. FIG. 2 shows an overall explanatory diagram of a system including such an upper-level advanced production management apparatus.

(32) 3. Overall Explanatory Diagram

(33) FIG. 2 shows an overall explanatory diagram illustrating a configuration of an overall production system including an advanced production management apparatus 300 positioned in a higher level than the production management apparatus 100. It is considered that, in many cases, a configuration similar to that shown in FIG. 2 is seen as a configuration of a production system in an actual factory or the like. In the example shown in FIG. 2, a plurality of machine tools 200a, 200b and 200c are connected to the production management apparatus 100. They may be connected by Local Area Network (LAN) such as EtherNet (registered trademark) or the like. In such a case, LAN is an example of low-speed communication. Alternatively, communication through wireless LAN or a mobile phone line may be used. These are also examples of low-speed communication.

(34) In each machine tool 200, the NC device 202 and the servo controller 204 are preferably connected by, for example, an internal bus of a computer (for example, PCI-Express or the like), or alternatively, may be connected by Universal Serial Bus (USB) or the like. These internal buses and the like are examples of medium-speed communication. The communication between the servo controller 204 and the amplifier may be of analog communication, or may be of high-speed optical fiber communication. These correspond to examples of high-speed communication.

(35) In FIG. 2, the advanced production management apparatus 300 as an upper-level device is connected to the production management apparatus 100. In the present embodiment, as described above, analysis of a tool life, that is, lifetime estimation and lifetime detection may be performed by the NC device 202 of each machine tool 200, or by the production management apparatus 100. Issuing a warning, stopping the operation of a machine tool or other operation based on such analysis result, that is, the estimation result of a lifetime and the detection result of a lifetime may be performed by the production management apparatus 100, or alternatively may be performed by an upper-level device (for example, the advanced production management apparatus 300 in FIG. 2).

(36) In the example shown in FIG. 2, the upper-level advanced production management apparatus 300 performs lifetime estimation and detection operation as well. In this example, the upper-level advanced production management apparatus 300 issues a warning or the like in addition to estimation and detection of a tool life, based on such estimation result and detection result. In an example, the upper-level advanced production management apparatus 300 performs comparison and monitoring with respect to, for example, main shaft torque, to estimate and detect a tool life. The upper-level advanced production management apparatus 300 further issues a warning or the like based on the estimation result and the detection result. In the example of FIG. 2, the advanced production management apparatus 300 as an example issues a warning to a maintenance management section 400 which makes a maintenance plan for a factory. Based on the warning, the maintenance management section 400 is capable of performing treatment such as preparation of a spare tool and replacement of a tool.

(37) Reduction in Data Amount

(38) As described above, in many cases and in general, communication closer to the motor 208 is promptly controlled through high-speed communication, but communication closer to a management section is performed through relatively-low-speed communication because a data band is less required. In such a case, it is not preferable that the data (servo data) of the motor 208 without any change are directly transmitted to an upper-level management apparatus or management section, from the viewpoint of the transmission data amount. The present embodiment achieves to provide more efficient management, by performing the first processing and the second processing to reduce data amount. The present embodiment further achieves to reduce a capacity of an external storage, and reduce processing load of an external management apparatus or the like, with the reduction of data amount, thereby enabling to efficiently estimate and detect a tool life.

(39) 4. Modifications

(40) (1) In the above-described embodiment, data are compressed by the first processing and the second processing. Alternatively, only one of them may be performed. If data are sufficiently reduced in amount only by one of them, effects can be exerted. Conversely, more types of processing such as a third processing may be added to the first processing and the second processing.

(41) (2) in the above-described embodiment, the current value is used as servo data in order to monitor the torque of the motor. Alternative other parameters may be used.

(42) (3) In the above-described embodiment, the squaring and integrating processing is taken as an example of the compression processing. Alternatively, other compression processing may be used.

(43) Although the embodiments according to the present invention have been described in detail as above, the above-described embodiments merely indicate specific examples as embodiments according to the present invention. The technical scope of the present invention is not limited to the above-described embodiments. The present invention is enabled to be variously modified without departing from the spirit thereof, and these modifications are also included in the technical scope of the present invention.

EXPLANATION OF REFERENCE NUMERALS

(44) 10 Production Management System 100 Production Management Apparatus 200, 200a, 200c Machine Tool 202 NC Device 204 Servo Controller 206 Amplifier 208 Motor 210 Detector 300 Advanced Production Management Apparatus 400 Maintenance Management Section