METHOD FOR DISPLAYING THE MACHINING IN A MACHINE TOOL

Abstract

The invention relates to a method for representing the machining operations in the machining area of a machine tool, wherein a tool or workpiece is scanned and the machining process is visualized. The invention relates furthermore to a corresponding machine tool and a corresponding system.

Claims

1. A method for representing machining operations in a machining area of a machine tool, in which a workpiece is machined by a tool with movement of the tool relative to the workpiece, comprising the steps of: before the start of machining, scanning, with a scanner, at least the workpiece and/or the tool and creating a three-dimensional data model is created therefrom; recording the model in a memory; during the machining of the workpiece, which includes a relative change of position of workpiece and tool, continually supplying relevant position information of the workpiece and/or tool to an image data processing unit; continually updating, in the image data processing unit, a three-dimensional data model from the memory with the position information; and displaying an updated, virtual image of workpiece and/or tool on a display unit.

2. A method according to claim 1, the step of scanning of the workpiece and/or tool takes place in the direction of a machining flow before or in the machining area.

3. A method according to claim 1, wherein a machine control unit, which causes a positional change to the workpiece relative to the tool by operating at least one drive unit, is provided, wherein the machine control unit transmits position information to the at least one drive and also supplies this position information to the image data processing unit.

4. A method according to claim 1, wherein at least one position sensor is provided to detect the relevant position of the workpiece and/or tool, which calculates the appropriate position information and supplies it continually to the image data processing unit.

5. A method according to claim 1, wherein the display unit defines a selectable viewing direction and/or in which cutting plane the virtual image is displayed and the image data processing unit prepares the data model accordingly with respect to the selectable viewing direction and displays the data model on the display unit.

6. A method according to claim 1, wherein the display unit is arranged to include a mode in which the display unit selectively allows display of future machining in the machining area, wherein the relevant current speed vector/s of the element/s moving in the machining area is calculated in the mode and from the calculation, the future machining calculated from the data model for the future point in time and displayed on the display unit.

7. A method according to claim 1, wherein a metal cutting machine tool comprising a motor spindle is provided as the machine tool, which motor spindle accommodates a tool for at least one rotative drive unit, and the motor spindle is also arranged to accommodate a scanner, wherein the scanner scans specifically during rotation and/or movement of the motor spindle.

8. A machine tool for the metal cutting machining of a workpiece by a tool, wherein a movement of the tool occurs relative to the workpiece in a machining area, comprising: at least one movement drive and a scanner, which scans at least the workpiece and/or the tool and creates a three-dimensional data model therefrom; a memory to store the data model; and an image data processing unit that continually receives relevant position information of the workpiece and/or tool during the machining, and wherein the image data processing unit continually updates the three-dimensional data model from the memory with the position information and displays an updated, virtual image of workpiece and/or tool on a display unit.

9. A machine tool according to claim 8, wherein the scanner is arranged in the machining area and on the machine tool, in a direction of machining flow before the machining area.

10. A machine tool according to claim 9, wherein (a) the scanner is firmly installed in the machining area, and wherein the scanner is protected by a cover during machining in the machining area or (b) the scanner is arranged to be mountable or usable on a tool tray, and wherein the tool tray carries a tool during the machining.

11. A machine tool according to claim 8, wherein during the scanning an at least partially wireless data connection is provided between the scanner and the memory.

12. A machine tool according to claim 10, wherein, to transmit data between the scanner and the memory, wherein one or more first contact face(s) and one or more second contact face(s) that are mutually co-acting are provided on the scanner, wherein the one or more first contact face(s) is/are arranged to be usable in the tool tray, and the one or more second contact face(s) is/are provided on the tool tray, and the memory is connected conductively with the one or more second contact face(s).

13. A machine tool according to claim 12, wherein, to transmit energy between the scanner, energy feed lines are provided on or in the tool tray, wherein the one or more first contact face(s) is/are provided on the scanner and are arranged to be usable in the tool tray, and the energy feed line is connected conductively with the second contact face(s).

14. A machine tool according to claim 13, wherein a compressed air-powered generator is provided on the scanner, which provides a power supply of the scanner, and the scanner is arranged to be used in or on the tool tray and is connected or connectable with a compressed air line such that the compressed air supply of the machine tool powers the generator of the scanner.

15. A system comprising: a machine tool and a scanning station provided in a machining flow before the machine tool, which comprises a scanner for scanning at least a workpiece and/or tool and creates a three-dimensional data model; a memory that saves the data model; an image data processing unit that continually receives relevant position information of the workpiece and/or tool during the machining, and wherein the image data processing unit continually updates the three-dimensional data model from the memory with the position information and displays an updated, virtual image of the workpiece and/or tool on a display unit.

Description

[0046] In the drawing the invention is specifically shown schematically in embodiments. In the drawings:

[0047] FIG. 1 shows a machine tool per the invention,

[0048] FIG. 2 shows a system per the invention,

[0049] FIG. 3 a machine tool per the invention.

[0050] In the figures, identical or corresponding elements are each identified by the same reference numerals and will not therefore, if not appropriate, be described again. The disclosures contained in the entire description are transferable correspondingly to the same parts with the same reference numerals or same component descriptions. The position specifications selected in the description, such as above, below, lateral, etc., are also related to the directly described and shown figure and can be transferred correspondingly to the new position in the case of a change of position. Furthermore, specific features or combinations of features from the illustrated and described different embodiments can represent independent inventive solutions or solutions per the invention.

[0051] FIG. 1 shows a machine tool 1 per an embodiment of the invention. The machine tool 1 is shown in two states, wherein a first state is shown with the encircled number 1 and a second state with the encircled number 2. The reference numerals, which are shown for the second state, have been marked with an apostrophe for better distinguishability. If nothing specific is marked subsequently on a status, the relevant embodiments shall apply basically for both states.

[0052] The machine tool 1 (or machining area 1 in the second state) comprises a machining area 10 (or machining area 10 in the second state). In this, a workpiece 2 (or workpiece 2 in the second state) is specifically located, which should be machined by means of the machine tool 1.

[0053] The machine tool 1 comprises a movement drive 11 (or movement drive 11 in the second state) and a thus connected tool tray 30 (or tool tray 30 in the second state). The movement drive 11 is also designed to hold and three-dimensionally position the tool tray 30, i.e. to move it. There are thus two possible movement directions shown in FIG. 1, namely in the horizontal direction and in the vertical direction. A further movement direction is transverse to the paper plane of FIG. 1. This allows a free positioning of the tool tray 30 in the machining area 10.

[0054] The workpiece 2 rests on an unspecified support. It is typically fixed here and/or clamped such that it retains its position exactly even upon exertion of a pressure by a tool.

[0055] In the first state, a scanner 4 is included in the tool tray 30. This scanner 4 is also designed to scan the machining area 10 of the machine tool 1 completely and specifically inclusive of the workpiece 2. The exact contours of the workpiece 2 can thereby be recorded. The movement drive 11 can specifically be used for this, by means of which the scanner 4 can be moved around the workpiece 2 or positioned at different locations adjacent to the workpiece 2. The scanned contours of the workpiece 2 can for example also be used to inspect the workpiece 2. They can for example be compared with stored target data. Any deviations can for example indicate a damaged workpiece or defective workpiece.

[0056] A scan of the machining area 10 can also specifically be used to carry out a comparison with target data. For example, damages or possible hazard sources such as foreign bodies can be thereby recognized.

[0057] The scanner 4 can not only be moved by the movement drive 11, but also can be rotated in the tool tray 30. This corresponds to a typical functionality of such a tool tray 30, in which for example drills can also be used for conventional drilling of holes, which are rotated in typical usage.

[0058] The scanner 4 can specifically scan on all sides, which is represented by the three dotted lines in FIG. 1, first state. This can for example be achieved by the rotatability just mentioned.

[0059] The scanning of workpiece 2 takes place preferably before the start of machining. This can occur specifically in the first state of FIG. 1. The data being relevant for the machining can thereby be collected, specifically relating to the visualization of the data described below.

[0060] The data generated by the scanner 4, which specifically reproduces the contour of workpiece 2 and the structure of the machining area 10, is supplied to a memory 5. This occurs in the present case through an electrical connection, which is produced through coacting contact faces on the scanner 4 and on the tool tray 30. An error-prone plug and complex wireless transmission can thereby be avoided.

[0061] The data stored in the memory 5 forms specifically the basis for a visualization of the machining process, which is described in more detail below. In the memory 5, data about various workpieces, different machining points and/or different tools can be saved.

[0062] An image data processing unit 7 is communicatively connected with the memory 5. The image data processing unit 7 is also formed to read the above-mentioned data, which was produced by the scanner. Further details about the functionality of the image data processing unit 7 will be given below.

[0063] In the second state, which is also visualized in FIG. 1 as previously mentioned above, the actual machining of the workpiece 2 occurs. The scanner 4 was therefore replaced by a tool 3 (or tool 3), in the form of a drill in the present case, which can drill holes into the workpiece 2. The tool 3 can also be moved three-dimensionally through the machining area 10 by means of the movement drive 11 as described above with reference to the scanner 4 and can furthermore be rotated such that a conventional drilling procedure is facilitated.

[0064] By means of the image data processing unit 7 being described above, the machining process, during which the workpiece 2 is machined using tool 3, can be visualized. A display unit 8 in the form of a screen also serves for this purpose. This screen is communicatively connected with the image data processing unit such that image data can be transmitted from the image data processing unit 7 to the screen and can be displayed there.

[0065] The image data processing unit 7 is also communicatively connected with the movement drive 11. The image data processing unit 7 thereby continually receives information about movements, which the movement drive 11 performs with the tool 3.

[0066] The image data processing unit 7 uses both the information read out from the memory 5 and the information concerning movements from the movement drive 11 to visualize the machining process. A known starting position of the tool 3 can for example thereby be used as the starting point and relative to this changes in the position of the tool 3 are calculated on the basis of data concerning the movements of the movement drive 11.

[0067] The data produced by the scanner 4 relating to the workpiece 2 is available through the memory 5. This means that the image data processing unit 7 is informed about the contours of the workpiece 2 in the starting state.

[0068] Based on the data concerning the movement of the tool 3, the image data processing unit 7 continually calculates whether a contact is occurring between the workpiece 2 and the tool 3. In case of such a contact, the image data processing unit 7 also calculates how the workpiece 2 is machined by the tool 3. This can for example mean that a penetration of the tool 3 into the workpiece 2 is recognized and a removal of material from the workpiece 2 is assumed at the relevant position.

[0069] Based on the aforementioned information and the employed calculations, the image data processing unit 7 creates a visualization of the machining process, which is displayed on the display unit 8. The visualization includes a visualized machining area 10v, a visualized workpiece 2v and a visualized tool 3v. Changes to the position of the tool 3v and changes to the contour of workpiece 2v, generated by a machining by means of tool 3v, can also thereby be displayed. This facilitates a visual inspection of the machining process in real-time for a user. It is thereby emphasized that the data concerning the workpiece 2 is not just based on an assumption, but on three-dimensional data being measured directly before the machining, which has been acquired by means of the scanner 4.

[0070] By means of the described procedure, it is also possible to carry out a projection of the machining process. A projection of the movement of the tool 3 can hereby be used in a similar way to a movement of the tool 3 being calculated or determined on the basis of received data. This enables the operator to visually inspect the estimated result of a certain machining process in advance before a corresponding machining takes place. By means of the not-shown input means for example, the user can select how many seconds or minutes in advance the planned machining should be displayed. On the basis of the relevant machining data, for example NC data, the image data processing unit 7 can then project the expected movement of the tool 3 and a resulting machining of workpiece 2 can also be projected. The representations of the visualized workpiece 2v and the visualized tool 3v can be accordingly adapted such that the user can recognize the expected machining.

[0071] If the user for example recognizes that the planned or projected machining of workpiece 2 would lead to an undesired result, the user can intervene in good time and for example terminate or change the machining process.

[0072] FIG. 2 shows a system according to the invention, which comprises a machine tool 1 and a scanning station 9. The machine tool 1 is formed in a similar manner as described above with reference to FIG. 1. It specifically comprises a tool tray 30, in which both a tool 3 and a scanner 4 can be used. As in the embodiment per FIG. 1, an electrical connection can be created between the scanner 4 and a memory 5 by means of not-shown contact faces.

[0073] The memory 5 is in this case not arranged externally to the image data processing unit 7, but rather integrated into this. This changes nothing of the above-described functionalities.

[0074] The scanning station 9 is also formed to scan workpieces 2 prior to the machining, specifically before their introduction into the machine tool 1 and to thereby record their contours. For this purpose, the scanning station 9 comprises a scanner 4, which is formed in a similar manner to the scanner 4 described above with reference to FIG. 1.

[0075] Three workpieces 2 are displayed in this case, namely a first workpiece 2a, a second workpiece 2b and a third workpiece 2c. These workpieces 2 are passed under the scanner 4 on a schematically shown conveyor belt, wherein their contours are recorded by means of the scanner 4.

[0076] The scanner 4 of scanning station 9 is connected with the memory 5 such that data being recorded by the scanner 4 can be written to the memory 5 and can be processed by the image data processing unit 7 in a similar manner as described above.

[0077] In the embodiment of FIG. 2, a spatial separation between the scanning process and the machining process therefore occurs. A scanning of the workpiece 2 to be machined occurs outside the machining area 10. The relevant workpiece 2 is only introduced into the machining area 10 after the scanning. In the normal case, a scanning within the machining area 10 can therefore be omitted, which specifically saves time.

[0078] The relevant workpiece 2 is typically placed in a defined position in the machining area 10 such that the image data processing unit 7 can execute a visualization and projection of the machining process in a very similar way as described above with reference to FIG. 1.

[0079] The system of FIG. 2 comprises furthermore an additional scanning station 9. This is used to scan different tools 3.

[0080] It is thus schematically shown that a plurality of tools 3 are attached to a drum 31. This facilitates a simple and automated storage and selection of tools 3 for machining within the machining area 10. The additional scanning station 9 comprises an additional scanner 4, which is also designed to scan tools 3 in the drum 31 or upon removal from the drum 31. The contours of the relevant tool 3 can thereby be defined. On one hand, this supplies original data for the calculation being executed in the image data processing unit 7. On the other hand, by comparison with prior data being based on scanning procedures or with target data, any change to the relevant tool 3 can thereby be recognized, which can for example be based on damages or wear. If such deviations are recognized, the tool 3 can for example be disposed of. A postprocessing can also be conducted.

[0081] By means of the embodiment shown in FIG. 2, a visualization of a machining procedure can be carried out in a very similar way as described above with reference to FIG. 1. The data obtained outside of the machining area 10 is thereby typically relied upon such that a scanning procedure within the machining area 10 can typically be omitted. Time is thereby generally saved, which facilitates a higher throughput of the tool machine 1.

[0082] It is however understood that a scanner 4 can also be used in the tool tray 30 in the embodiment shown in FIG. 2 such that a scanning within the machining area 10 can be executed in a way similar to that described above with reference to FIG. 1. This can specifically then occur if a monitoring during a machining procedure is required or if the data produced before the machining comprises visual discrepancies.

[0083] FIG. 3 comprises a machine tool 1, which shows an alternative embodiment in comparison to the machine tool 1 shown in FIG. 1. In the embodiment per FIG. 3, the scanner 4 is not clamped by the tool tray 30, instead it is in fact moveably mounted to the upper side on the cover of the machining area 10. The scanner 4 can thereby be displaced such that a scanning of the entire machining area 10 is possible. Thus the initial mounting of a scanner 4 in the tool tray 30 before the machining process and the substitution of a tool 3 after the scanning can thereby be avoided. This can specifically reduce the machining time. In the embodiment per FIG. 3, the scanner 4 can also move along a predefined line such that specifically in the case where its position is measured simultaneously, irrespective of the movement drive 11, a particularly exact position of the scanner 4 can be determined.

[0084] Typically in the embodiment of FIG. 3, the workpiece 2 is introduced into the machining area 10 and then the machining area 10 including the workpiece 2 is measured by means of the scanner 4. The scanner 4 is thereby typically moved over a certain route. The thus-recorded data is saved in a memory 5 as described in the other embodiments, which the image data processing unit 7 can in turn access. This in turn also receives data about the movements of the movement drive 11 such that the above-described visualization can be advantageously executed.

[0085] The state during the scanning is identified in FIG. 3similarly to in FIG. 1as the first state with the number 1 in a circle. The state during machining is in contrast identified as the second state with the number 2 in a circle.

[0086] An image data processing unit 7 is continually provided with the relevant position information of the workpiece 2 and/or tool 3 during the machining. A position monitoring unit 6 is provided for this purpose, which is for example a part of the machine control of the machine tool 1.