Thermal image assisted machining device, positioning device and method thereof

Abstract

The present application discloses a thermal image assisted machining device, a positioning device and a method thereof. The thermal image assisted machining method comprises the following steps. A reference component is prepared. A reference positioning point or a reference positioning surface is established by using the reference component. A tool or a grinding tool to be measured is positioned by using the reference positioning point or the reference positioning surface. A measured positioning point or a measured positioning surface is obtained according to a thermal image. By using the above method, the present application can be used for the assisted positioning and wear detection of the tool or the grinding tool, and for the measurement of the size, angle or flatness of the object to be measured. Therefore, the present application can avoid the problems of increased equipment downtime and retooling errors caused by manual and visual processing or measurement.

Description

TECHNICAL FIELD

[0001] The present application relates to a processing method, and in particular to a thermal image assisted processing device, a positioning device and a method thereof. BACKGROUND

[0002] Generally, the tool positioning and wear detection of the tool machine during processing are mostly manually measured and visually observed. However, the measurement and setting of the tool feed length, the workpiece size and the initial contact with the blank surface by this way will cause the increase of idle time and the visual error. In addition, the tool and the workpiece are measured outside the machine, and the tool needs to be re-calibrated in length and position after installation due to the locking error. In addition, if optical image recognition and measurement are used, the optical image recognition is easily affected by environmental factors such as light source and surface material, and a high-resolution camera is required, so the requirements of the image processing equipment, cost and technology are relatively high.

[0003] In addition, the traditional manual tool setting method is to manually move the tool by the processing personnel, so that the tool tip point gradually approaches the workpiece until the cutting chips are generated by the naked eye, and then the coordinate position in this direction is regarded as the tool setting coordinate of the axis. However, the error value of manual tool setting by this method is about 10µm or even higher, so the error value may be different due to the eye condition, experience, environmental light and other factors of the processing personnel. SUMMARY

[0004] The present application discloses a thermal image assisted processing device and a method thereof for assisting the positioning of the tool or the grinding tool before and after processing, wear detection and measurement of the size, angle or flatness of the measured object.

[0005] The present application also discloses a thermal image assisted positioning device for aligning the tool or the grinding tool.

[0006] According to an aspect of the present application, a thermal image assisted processing method is provided, comprising the following steps. A reference component is prepared. A reference positioning point or a reference positioning surface is established by the reference component. A measured tool or a measured grinding tool is positioned by the reference positioning point or the reference positioning surface. A measured positioning point or a measured positioning surface is obtained according to the thermal image.

[0007] According to an aspect of the present application, a thermal image assisted processing device is provided for positioning or measuring a measured object. The thermal image assisted processing device comprises a thermal image sensing module and a processing unit. The thermal image sensing module synchronously monitors the thermal temperature rise of the measured object. The processing unit comprises a controller. When at least one temperature rise hot spot of the measured object is monitored by the processing unit according to the thermal image, the mechanical coordinate conversion is performed by the controller to obtain at least one position coordinate information.

[0008] According to one aspect of the present invention, a thermal imaging-assisted positioning device is provided for locating a tool or a mold. The thermal imaging-assisted positioning device includes a thermal imaging sensing module and a processing unit. The thermal imaging sensing module simultaneously monitors the thermal temperature rise of the tool or mold. When the processing unit detects at least one temperature rise hotspot on the tool or mold based on the thermal image, it issues a warning signal.

[0009] In order to better understand the above and other aspects of the present invention, the following embodiments are specifically described in detail with reference to the accompanying drawings: BRIEF DESCRIPTION OF THE DRAWINGS

[0010] FIG. 1A is a schematic diagram of a thermal imaging assisted processing device according to an embodiment of the present invention;

[0011] FIG. 1B and FIG. 1C They are respectively flow charts of the thermal imaging assisted processing method according to an embodiment of the present invention;

[0012] FIG. 2 They are respectively flow charts of a thermal imaging assisted machining method for tool positioning and wear detection according to an embodiment of the present invention;

[0013] FIG. 3A and FIG. 3B for FIG. 2 An example operation diagram of the thermal image-assisted machining method for tool (e.g., turning tool) positioning.

[0014] FIG. 4A to FIG. 4D They are FIG. 2 Two example operation diagrams of the thermal imaging-assisted machining method for tool (e.g., turning tool) wear detection.

[0015] FIG. 5A and FIG. 5B for FIG. 2 Another example operation diagram of a thermal imaging-assisted machining method for positioning a tool (such as a drill or a milling cutter);

[0016] FIG. 6A to 6D The pictures are FIG. 2 Two more example operation diagrams of the thermal imaging-assisted machining method for tool (e.g. milling cutter) wear detection.

[0017] FIG. 7A to FIG. 7D They are FIG. 2 Another example operation diagram of the thermal imaging-assisted machining method for tool (such as drill or milling cutter) wear detection.

[0018] FIG. 8 are respectively flow charts of a thermal imaging-assisted machining method for positioning and wear measurement of abrasive tools (such as grinding wheels) according to an embodiment of the present invention;

[0019] FIG. 9A and FIG. 9B is FIG. 8 An example operation diagram of a thermal image assisted machining method for positioning of a grinding tool (e.g. a grinding wheel) in

[0020] FIG. 10A and FIG. 10B is FIG. 8 Another example operation diagram of a thermal image assisted machining method for positioning of a grinding tool (e.g. a polygonal grinding wheel) in

[0021] FIG. 11A and FIG. 11B Fig. is FIG. 8 An example operation diagram of a thermal image assisted machining method for wear measurement of a grinding tool (e.g. a grinding wheel) in

[0022] FIG. 12A and FIG. 12B are two example operation diagrams of a thermal image assisted machining method for angle measurement and flatness measurement, respectively.

[0023] FIG. 13A to FIG. 13D are example operation diagrams of a thermal image assisted positioning method for alignment of a tool or grinding tool, respectively.

[0024] Legend of symbols

[0025] 100: machine tool

[0026] 102: multi-axis servo drive motor

[0027] 103: blank (or piece to be machined)

[0028] 104: tool

[0029] 105: dresser

[0030] 106: grinding tool

[0031] 107: reference positioning point (surface)

[0032] 108: intended machining position

[0033] 108’: actual machining position

[0034] 109: cutting position of reference tool

[0035] 110: thermal image assisted machining device

[0036] 110’: thermal image assisted positioning device

[0037] 111: grinding wheel

[0038] 112: processing unit

[0039] 113: controller

[0040] 114: input unit

[0041] 116: thermal image sensing module

[0042] 117: precisely ground surface (measured reference surface)

[0043] 121: reference tool

[0044] 122, 123: machining tools

[0045] MG: thermal image

[0046] d: tolerance

[0047] H1, H2, H3: hot spots of temperature rise DETAILED DESCRIPTION

[0048] Example implementations will now be described more fully with reference to the accompanying drawings. Example implementations may, however, be implemented in many different forms and should not be construed as limited to the examples set forth herein; rather, these implementations are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the example implementations to those skilled in the art. The described features, structures, or characteristics can be combined in one or more implementations.

[0049] In addition, the drawings are to be considered in all respects as illustrative and not restrictive; identical reference numerals have been used, where possible, to denote identical or similar features, and thus repetition of the description thereof will be omitted. Some of the blocks in the diagrams are functional blocks that do not necessarily have to be implemented in the described order. The functional blocks can be implemented by software, or in one or more hardware modules or integrated circuits, or in different network and / or processor devices and / or microcontroller devices.

[0050] It should be noted that the embodiments of the present application and the features in different embodiments can be combined with each other without conflict.

[0051] FIG. 1A a schematic diagram of a thermal image assisted machining device 110 for tool 104 or grinding tool 106 positioning and wear measurement according to an embodiment of the present application, FIG. 1B and FIG. 1CFlowcharts of the thermal image assisted machining method according to embodiments of the present application are shown in FIGS. 1-3. In the embodiments, a thermal image assisted machining device 110 can be used in a machine tool 100, such as a computer numerical control (CNC) machine tool, including a lathe, a milling machine, a drilling machine, or a grinding machine, to perform cutting, milling, drilling, or grinding machining processes on a workpiece (or workpiece-to-be-machined) 103. A user can input instructions to a multi-axis servo drive motor 102 of the machine tool 100 via a controller 113 to drive a tool 104 or a grinding tool 106 to move and perform machining on the workpiece 103 fixed on a machine table to complete a machining product. Before or after the workpiece 103 is machined, the user can also input instructions to the multi-axis servo drive motor 102 of the machine tool 100 via the controller 113 to drive a reference tool to move and perform positioning and tolerance measurement on the workpiece 103 fixed on the machine table to ensure that the tolerance of the machined product is within an allowable tolerance range. Alternatively, before the grinding tool 106 grinds the workpiece 103, the user can trim a grinding surface of the grinding tool 106 with a sharp end of a trimmer 105 as a reference positioning point. After the grinding tool 106 grinds the workpiece 103 for a period of time, the user can trim the grinding tool 106 precisely and perform wear detection of the grinding tool 106 via the trimmer 105 to ensure that the tolerance of the machined product is within the allowable tolerance range.

[0052] Please refer to FIG. 1A , the thermal image assisted machining device 110 is used to assist positioning of the tool 104 or the grinding tool 106 before and after machining and to measure the size, angle, or flatness of a measured object (e.g., the workpiece 103). The thermal image assisted machining device 110 includes a thermal image sensing module 116 and a processing unit 112. The processing unit 112 includes the controller 113 and an input unit 114, such as a computer, to input instructions. The thermal image sensing module 116 synchronously monitors thermal temperature rise of the workpiece and the tool when they are in contact with each other, and the processing unit 112 can determine whether the tool 104 and the workpiece 103 are in contact with each other or calculate the size, angle, or flatness of the measured object according to a thermal image MG when a thermal hot spot H1 is initially generated.

[0053] Please refer to FIG. 1B , first, a reference component, such as a reference tool or a trimmer, is prepared in step S11. A reference positioning point (surface) is established with the reference component in step S12. The machined tool (grinding tool) is positioned with the reference positioning point (surface) in step S13. Then, whether a thermal hot spot appears in a thermal image is determined to obtain a measured positioning point (surface) in step S14. In this way, positioning measurement of the machined tool (grinding tool) is completed to facilitate subsequent mass production machining.

[0054] Please refer to FIG. 1CThe wear detection process of the present application is shown in FIG. 4. First, in step S15, a reference part is established to determine the measured point (surface), in step S16, the measured point (surface) and the tracking offset cutting according to the specified machining instructions are performed, in step S17, whether the size of the workpiece to be machined meets the tolerance standard is determined according to whether the temperature rise hot spot appears in the thermal image, if it does not meet the standard, step S18 is performed to adjust the wear value, and the workpiece to be machined is reprocessed or corrected. If it meets the standard, the next mass production machining is continued.

[0055] The thermal image assisted machining method according to different embodiments of the present application is described in detail as follows. FIG. 2 The flowcharts of the thermal image assisted machining method for tool 104 positioning and wear detection according to embodiments of the present application are shown in FIGS. 1A and 1B, respectively. FIG. 3A The flowcharts of the thermal image assisted machining method for tool 104 positioning and wear detection according to embodiments of the present application are shown in FIGS. 1A and 1B, respectively. FIG. 3B The flowcharts of the thermal image assisted machining method for tool 104 positioning and wear detection according to embodiments of the present application are shown in FIGS. 1A and 1B, respectively. FIG. 2 An example operation diagram of the thermal image assisted machining method for tool 104 (e.g. turning tool) positioning in the present application is shown in FIG. 2A. FIG. 4A An example operation diagram of the thermal image assisted machining method for tool 104 (e.g. turning tool) positioning in the present application is shown in FIG. 2A. FIG. 4D An example operation diagram of the thermal image assisted machining method for tool 104 (e.g. turning tool) positioning in the present application is shown in FIG. 2A. FIG. 2 Two example operation diagrams of the thermal image assisted machining method for tool 104 (e.g. turning tool) wear detection in the present application are shown in FIGS. 5A and 5B, respectively. FIG. 2 Another example operation diagram of the thermal image assisted machining method for tool 104 (e.g. drill or milling tool) positioning in the present application is shown in FIG. 6A. FIG. 2 Two other example operation diagrams of the thermal image assisted machining method for tool 104 (e.g. milling tool) wear detection in the present application are shown in FIGS. 7A and 7B, respectively. FIG. 2 Two other example operation diagrams of the thermal image assisted machining method for tool 104 (e.g. drill or milling tool) wear detection in the present application are shown in FIGS. 8A and 8B, respectively. FIG. 8 The flowcharts of the thermal image assisted machining method for tool 104 (e.g. turning tool) positioning and wear detection according to embodiments of the present application are shown in FIGS. 1A and 1B, respectively. FIG. 8 An example operation diagram of the thermal image assisted machining method for tool 104 (e.g. turning tool) positioning in the present application is shown in FIG. 2A. FIG. 8 Another example operation diagram of the thermal image assisted machining method for tool 104 (e.g. turning tool) positioning in the present application is shown in FIG. 2A. FIG. 8 An example operation diagram of the thermal image assisted machining method for tool 104 (e.g. turning tool) positioning in the present application is shown in FIG. 2A.

[0056] Please refer to FIG. 2 , 3Aand 3B. First, step S21, the reference tool 121 is positioned. Step S22, the reference tool 121 cuts on the blank 103 to establish the reference positioning point (surface) 107, where the coordinate of the reference tool 121 tip is known. Step S23, the machining tool 122 is cyclically approached to the blank 103, and the cutting stroke is continuously performed, but has not yet contacted the blank 103. Step S24, the thermal image sensing module 116 synchronously monitors whether there is a thermal temperature rise. If the temperature rise hot spot H1 is monitored, it indicates that the machining tool 122 has just contacted the blank 103, that is, the reference positioning point (surface) 107 is reached, and in step S25, the mechanical coordinate conversion is performed by the controller 113 to complete the positioning of the machining tool 122 (i.e. the coordinates of the measured positioning point are obtained). If no temperature rise hot spot H1 is monitored, return to step S23, continue to approach the blank 103. The so-called mechanical coordinate conversion refers to the position or coordinate reached by the machining tool 122 after multiple cycles of cutting by the controller 113.

[0057] Please refer to FIG. 3A The coordinate position of the tip of the reference tool 121 described above is known, and after the reference tool 121 completes positioning, it does not participate in subsequent mass production cutting, but only serves as a positioning tool, which can be used for a long time without wear, and does not need to go through the process of positioning the reference tool 121 every time. In addition, when the reference tool 121 cuts the blank 103, the processing unit 112 of FIG. 1 can determine the position of the blank 103 and the size of the blank 103 through numerical analysis.

[0058] Please refer to FIG. 3B The coordinate position of the tip of the machining tool 122 described above is unknown, so the position of the reference positioning point (surface) 107 is established by the reference tool 121. Then, the machining tool 122 is cyclically approached to the blank 103 until it just contacts the blank 103 to generate cutting (e.g. 1 pm cutting thickness or more, determined by the accuracy of the feed mechanism). At this time, the thermal image MG instantaneously displays the temperature rise hot spot H1 generated when the machining tool 122 cuts the blank 103, so that the controller 113 of the processing unit 112 performs mechanical coordinate conversion of the tip coordinate of the machining tool 122. For example, the tip coordinate of the machining tool 122 is approximately equal to the reference positioning point (surface) 107 established by the reference tool 121 minus the distance of the machining tool 122 approaching the reference positioning point (surface) 107 in the same direction. The minimum approach distance is determined by the minimum feed machining accuracy of the tool machine 100 (which can be 1 pm or more), but the present application is not limited thereto.

[0059] After the positioning of the machining tool 122 described above is completed, further wear detection of the machining tool 122 can be performed. Please refer to FIG. 2. First, in step S26, the processing knife 122 starts to perform mass production cutting. At this time, the processing knife 122 continues to wear slightly and reduces its length, so that the processing knife 122 has a wear amount after cutting (that is, the initial size of the processing knife 122 minus the remaining size after cutting). Step S27, when the mass production cutting is completed, the reference knife 121 repeats the last processing instruction of the processing knife 122 to perform tracking offset cutting stroke. For example, the reference knife 121 tracks and moves on the blank 103 and offsets the cutting surface of the blank 103 by a tolerance or a predetermined deviation value. Step S28, synchronously monitor whether there is a temperature rise hotspot H1 on this cutting surface from the thermal image MG. If the temperature rise hotspot H1 is detected, in step S29, it is determined that the wear amount of the processing knife 122 is greater than the tolerance (or the predetermined deviation value), indicating that the dimensional tolerance of the blank 103 is greater than the deviation value, and the wear value needs to be adjusted (such as FIG. 1C If no temperature rise hotspot H1 is detected, and the wear of the cutting tool 122 is determined to be less than the tolerance (or predetermined deviation), the process returns to step S26 and continues with the next round of mass production cutting. The tolerance is, for example, the difference in size permitted by the processing personnel for the finished product of the qualified blank 103.

[0060] Please refer to FIG. 4A and FIG. 4B , which illustrates an embodiment where the wear of the machining blade 122 is less than the tolerance d. In this embodiment, the machining blade 122 is gradually worn after multiple cycles of machining, so that the actual cutting amount of the machining blade 122 gradually becomes less than the expected cutting amount. Therefore, it is necessary to perform a wear test on the machining blade 122 to confirm whether the wear of the machining blade 122 is within the allowable tolerance range (which can be 1µm or greater). FIG. 4A As shown, when the wear amount of the processing knife 122 is still small, the processing knife 122 cuts on the expected processing position 108, and then, as shown in FIG. FIG. 4B As shown, reference blade 121 repeats the final machining instruction of processing blade 122, tracking along stock 103 and offsetting outward by a tolerance d. As a result, cutting position 109 of reference blade 121 deviates from intended machining position 108 and therefore does not contact the surface of stock 103. At this point, no thermal rise occurs, and therefore no hot spot H1 is displayed in thermal image MG, indicating that the wear of processing blade 122 is less than tolerance d.

[0061] Please refer to FIG. 4C and 4D , which illustrates an embodiment in which the wear of the machining tool 122 is greater than the tolerance d. FIG. 4C As shown, when the wear of the processing knife 122 is too large, the processing knife 122 does not cut at the expected processing position 108, so that the actual processing position 108' deviates from the expected processing position 108 (greater than or equal to the tolerance d). Then, as shown in FIG.FIG. 4D As shown, the reference knife 121 repeats the last processing instruction of the processing knife 122 and moves along the blank 103 and deviates outward by a tolerance d. However, due to insufficient cutting amount of the processing knife 122, the reference knife 121 still contacts the surface of the blank 103, and a temperature rise hotspot H1 is displayed in the thermal image MG, indicating that the wear of the processing knife 122 is greater than the tolerance d.

[0062] As can be seen from the above description, when the temperature rise hot spot H1 is displayed in the thermal image MG, it means that the wear of the processing blade 122 exceeds the allowable tolerance range. At this time, the processing blade 122 can be corrected for wear. FIG. 2 The positioning measurements in steps S22 to S25 are automatically achieved.

[0063] like FIG. 2 As described above, in step S29, when the dimensional tolerance is greater than the deviation value, refer to steps S22 to S25 to perform wear compensation on the processing knife 122. Similar practices include the following: in step S22, the reference knife 121 is used to cut on the blank 103 to establish a new reference positioning point. In step S23, the processing knife 122 is used to cyclically approach the blank 103 until it cuts into the blank 103, and cutting is performed at the new reference positioning point. In step S24, the thermal image MG is synchronously monitored to see whether there is a temperature rise hotspot H1. If the temperature rise hotspot H1 is detected, in step S25, the processing knife 122 is positioned (i.e., the measured position is obtained) through mechanical coordinate conversion to complete the wear compensation of the processing knife 122.

[0064] Please refer to 5A and FIG. 5B , and FIG. 3A and FIG. 3B The thermal imaging-assisted machining method is similar to that used in the present embodiment, both of which are used to position the tool 104. Identical or corresponding parts will not be further described. The difference between the two embodiments is that the positioning tool 123 in this embodiment is a drill or milling cutter. The drill or milling cutter can be moved in the XY plane, XZ plane, or YZ plane until it contacts the surface of the blank 103 and produces a cut (e.g., a milling thickness of 1µm or greater). At this point, the thermal image MG instantly displays the temperature rise hotspot H1 of the tool 123 as it mills the blank 103, allowing the processing unit 112 to complete the positioning of the tool 123 (i.e., determine the measured position) through mechanical coordinate conversion.

[0065] After the positioning of the processing knife 123 is completed, the wear of the processing knife 123 can be further tested after the processing knife has been mass-produced for a period of time or a number of times. FIG. 6A to FIG. 6D and FIG. 7A to FIG. 7D , and FIG. 4A to FIG. 4DThe thermal image assisted machining method of the grinding tool 123 is similar to the thermal image assisted machining method of the cutting tool 123, and the same or corresponding parts are not described again. The difference between the two methods is that the grinding tool 123 in the present embodiment is a drill or a milling cutter. The drill or the milling cutter gradually wears (e.g. the length or diameter of the tool wears) after multiple cycles of machining, so that the actual cutting amount gradually becomes smaller than the expected cutting amount. Therefore, it is necessary to detect the wear of the grinding tool 123 to determine whether the wear of the grinding tool 123 is within the allowable tolerance (which can be 1 µm or more). For example, as shown in FIG. 6A and FIG. 7A When the wear of the grinding tool 123 is small, the grinding tool 123 mills at the expected machining position, and then, as shown in FIG. 6B and FIG. 7B The reference tool 121 repeatedly traces the last machining instruction of the grinding tool 123 on the blank 103 and shifts outward by a tolerance, so the reference tool 121 does not contact the surface of the blank 103. At this time, there is no temperature rise hot spot H1 indicating cutting in the thermal image MG, indicating that the wear of the grinding tool 123 is less than the tolerance. In addition, as shown in FIG. 6C and FIG. 7C When the wear of the grinding tool 123 is large, the grinding tool 123 does not cut at the expected machining position, so that the actual machining position 108' deviates from the expected machining position 108, and then, as shown in FIG. 6D and FIG. 7D The reference tool 121 repeatedly traces the last machining instruction of the grinding tool 123 on the blank 103 and shifts outward by a tolerance, but because the cutting amount of the grinding tool 123 is insufficient, the reference tool 121 will contact the surface of the blank 103, and a temperature rise hot spot H1 will be displayed in the thermal image MG, indicating that the wear of the grinding tool 123 is greater than the tolerance.

[0066] In addition, similar to the method of the turning tool, the size correction of the subsequent drill or milling cutter can be automatically achieved by the positioning measurement of steps S22 to S25 in the above FIG. 2 , which will not be described again.

[0067] The following describes a thermal image assisted machining method for positioning and wear detection of the grinding tool 106 (e.g. a grinding wheel). Please refer to FIG. 8, first, step S81, the dresser 105 is positioned, the coordinates of the tip of the dresser 105 are known, and the tip of the dresser 105 is used as a reference positioning point. Step S82, the grinding wheel 111 is cyclically approached to the dresser 105 until the dresser 105 is contacted. Step S83, whether a thermal temperature rise occurs is synchronously monitored from the thermal image MG. If the temperature rise hot spot H1 is monitored, it indicates that the grinding wheel 111 just contacts the dresser 105, then, in step S84, the accurate dressing is performed according to the required dressing amount to establish the accurate grinding surface 117 (i.e. the measured positioning surface). If the temperature rise hot spot H1 is not monitored, it returns to step S82, and the approaching to the dresser 105 is continuously performed.

[0068] Please refer to FIG. 9A The above-mentioned dresser 105 is positioned, and the hardness and strength of the dresser 105 are far higher than those of the grinding wheel 111, so that the dresser 105 can be used for a long time without wear and tear, and the process of positioning the dresser 105 is not required each time. In addition, when the dresser 105 dresses the grinding wheel 111, the processing unit 112 can determine the position of the accurate grinding surface 117 of the grinding wheel 111 through numerical analysis of the controller.

[0069] Please refer to FIG. 9B The tip of the dresser 105 is used as a reference to accurately dress the surface of the grinding wheel 111 to establish the accurate grinding surface 117 (i.e. the measured positioning surface), so that the grinding wheel 111 recovers the complete grinding force. At this time, the temperature rise hot spot H1 of the dressing of the grinding wheel 111 is displayed in the thermal image MG in real time, so that the processing unit 112 can complete the positioning of the grinding wheel 111 (i.e. the measured positioning point) through mechanical coordinate conversion. For example, the positioning of the grinding wheel 111 is calculated by adding the coordinates of the tip of the dresser to the moving coordinates of the controller.

[0070] In addition, please refer to FIG. 10A and FIG. 10B If the grinding wheel is in the form of a polygon, the grinding wheel 111 is cyclically approached to the dresser 105 until the dresser 105 is contacted, and the side surface of the grinding wheel 111 and the side surface of the dresser 105 are contacted at this time, then, the grinding wheel surface is accurately dressed according to the required dressing amount to establish the accurate grinding surface 117, as described above in step S84.

[0071] After the above-mentioned positioning of the grinding tool 106 is completed, the wear detection of the grinding tool 106 can be further performed. Please refer to FIG. 8. First, in step S85, the grinding wheel 111 performs mass production grinding and cutting. At this time, the grinding wheel 111 continues to wear slightly and reduces the diameter of the grinding wheel 111, so that the grinding wheel 111 has a certain amount of wear after grinding (that is, the initial grinding wheel size minus the remaining size after grinding). In step S86, the grinding wheel 111 repeats the processing instruction to perform tracking offset cutting. For example, the grinding wheel 111 tracks and moves on the blank 103 and is offset outward relative to the grinding surface of the blank 103 by a tolerance d or a predetermined deviation value. In step S87, the grinding surface is synchronously monitored from the thermal image MG to see if there is a thermal temperature rise. If a temperature rise hotspot H1 is detected, in step S88, it is determined that the wear of the grinding wheel 111 is greater than the tolerance d (or the predetermined deviation value), indicating that the dimensional tolerance of the blank is greater than the deviation value, and the wear value needs to be adjusted (such as FIG. 1C If no temperature rise hotspot H1 is detected and the wear of the grinding wheel 111 is determined to be less than the tolerance d (or the predetermined deviation value), the process returns to step S85 and the grinding process continues.

[0072] Please refer to FIG. 11A and FIG. 11B , which respectively depict two embodiments in which the wear of the grinding wheel 111 is less than and greater than or equal to the tolerance. In this embodiment, the grinding wheel 111 is gradually worn after multiple cycles of processing, so that the actual cutting amount of the grinding wheel 111 is gradually less than the expected cutting amount. Therefore, it is necessary to perform a wear test on the grinding wheel 111 to confirm whether the wear amount of the grinding wheel 111 is within the allowable tolerance range. First, the grinding wheel 111 is accurately dressed with a dresser 105, and the moving coordinates of the controller are obtained to establish a reference positioning surface 107 on the grinding wheel surface, and the blank 103 is tracked and offset cut with the reference positioning surface 107. FIG. 11A As shown in FIG11B , when the wear of grinding wheel 111 is minimal, grinding wheel 111 tracks on stock 103 and deflects outward by a tolerance d, preventing the grinding wheel from contacting the stock 103 surface. In this case, the thermal image MG does not display the grinding hotspot H1, indicating that the wear of grinding wheel 111 is less than the tolerance d. As shown in FIG11B , when the wear of grinding wheel 111 is excessive, even though grinding wheel 111 tracks on stock 103 and deflects outward by a tolerance d, the grinding force of grinding wheel 111 is insufficient, so grinding wheel 111 still contacts the stock 103 surface. This results in the display of the hotspot H1 in the thermal image MG, indicating that the wear of grinding wheel 111 is greater than the tolerance.

[0073] From the above description, it can be seen that when the temperature rise hot spot H1 is displayed in the thermal image MG, it means that the wear of the grinding wheel 111 is not within the allowable tolerance range. At this time, the wear of the grinding wheel 111 can be corrected. FIG. 8 The wear compensation of the grinding wheel 111 is generally the same as that of the step S82 to S84. FIG. 8The similar, including: with dresser 105 to dress the surface of the grinding wheel, and with thermal image MG synchronous monitoring the thermal temperature rise of the grinding wheel surface, then, according to the thermal image MG, on the grinding wheel surface to establish a new accurate grinding surface (that is, the measured positioning surface), to carry out the wear correction of grinding wheel 111.

[0074] Please refer to FIG. 12A And FIG. 12B , in addition to the above-mentioned each embodiment of the tool 104, the auxiliary positioning and wear detection of grinding tool 106, the thermal image assisted processing method can also be used for angle measurement and flatness measurement of workpiece (such as blank 103), please refer to FIG. 1B The positioning measurement process is described. In the 12A figure, with an already positioned reference cutter 121 or milling cutter or grinding tool to approach the surface of blank 103, and with thermal image MG synchronous monitoring the thermal temperature rise of the surface of blank 103, to obtain the first temperature rise hot spot H1, through the controller mechanical coordinate conversion to obtain the first position coordinate information (that is, the first positioning point or the first positioning surface). In addition, with an already positioned reference cutter 121 or milling cutter or grinding tool to approach the surface of blank 103, and with thermal image MG synchronous monitoring the thermal temperature rise of the surface of blank 103, to obtain the second temperature rise hot spot H2, through the controller mechanical coordinate conversion to obtain the second position coordinate information (that is, the second positioning point or the second positioning surface). The first positioning point and the second positioning point are separated by a predetermined distance, according to the distance and height difference between the first positioning point and the second positioning point, the slope and inclination angle of the surface of blank 103 are calculated, to complete the angle measurement.

[0075] In FIG. 12B , similarly to the above method, with thermal image MG synchronous monitoring the thermal temperature rise of the surface of blank 103, to obtain at least three temperature rise hot spots H1 to H3 (that is, at least three positioning points or positioning surfaces). According to the plane formed by at least three positioning points and the height difference, the flatness of the surface of blank 103 is calculated, to complete the flatness measurement.

[0076] Please refer to FIG. 13A to FIG. 13D , which respectively show the example operation diagram of the thermal image assisted positioning method for tool or grinding tool alignment. FIG. 13A For similar to FIG. 3B thermal image assisted positioning method for tool (such as turning tool), FIG. 13B For similar to FIG. 5B thermal image assisted positioning method for tool (such as drill or milling cutter), FIG. 13C For similar to FIG. 11B thermal image assisted positioning method for grinding tool (such as grinding wheel), FIG. 13D For similar to FIG. 12AA thermal image assisted positioning method for a tool (e.g. drill or milling cutter) is disclosed. In the embodiment, the thermal image assisted positioning device 110' comprises a thermal image sensing module 116 and a processing unit 112. The thermal image sensing module 116 can monitor the thermal temperature rise of the tool 104 or grinding tool 106 when it contacts the workpiece 103 (or piece to be processed). When the processing unit 112 detects at least one temperature rise hot spot H1 of the tool 104 or grinding tool 106 according to the thermal image MG, the processing unit 112 sends a prompt signal. The processing unit 112 can include a processor and a firmware (firmware) or controller to execute an application program, such as a computer or a mobile communication device.

[0077] In the embodiment, the prompt signal is at least one of a sound signal emitted by a horn or a buzzer, a light signal emitted by a flash or a light source such as an LED, and an image signal generated by a screen. Through the above positioning method, the operator can manually operate the tool 104 or grinding tool 106 to move along a predetermined direction (e.g. cutting direction) so that the tool tip point or grinding surface gradually approaches the workpiece 103 (or piece to be processed). When the tool tip contacts the workpiece 103 (or piece to be processed), the workpiece 103 generates heat due to the micro-cutting of the tool tip or grinding surface. When the thermal image sensing module 116 detects the temperature rise hot spot H1, the processing unit 112 sends a prompt signal (such as a flash, a buzzer, an image, etc.) to the operator, so that the operator knows that the predetermined direction (e.g. cutting direction) is completed.

[0078] The above-mentioned thermal image assisted positioning tool error can be as low as 1 µm, which is less than the error value (about 10 µm) of manual tool setting. The tool error value of the embodiment has a high repeatability, which greatly reduces the dependence on the operator's naked eye judgment.

[0079] The thermal image assisted processing device and the assisted processing method according to the above-mentioned embodiments of the present application can be used for the assisted positioning and wear detection of tools or grinding tools, and for measuring the size, angle or flatness of the measured object. Therefore, the present application can avoid the problems of increased equipment downtime, error of re-tooling, etc. caused by manual and visual measurement. At the same time, the thermal image measurement technology replaces the traditional size measurement and general optical image recognition and monitoring, which is more convenient and low-cost in operation, not easily affected by environmental factors (including light source, surface material, etc.), and the installation and measurement of the thermal image sensing module are easy, do not need to be accurately corrected, and the measurement precision is the minimum effective movement distance of the machine (the processing precision can be 1 µm or more), so it can meet the requirements of the processing precision of the machine tool.

[0080] In summary, although the present application is disclosed in connection with the above embodiments, it is not intended to limit the present application. Those skilled in the art can make various modifications and improvements without departing from the spirit and scope of the present application. Therefore, the scope of protection of the present application should be defined by the appended claims.

Claims

1. A thermal image assisted machining method, comprising: establishing a reference location point or surface with a reference part; positioning a machining tool with the reference location point or surface; and determining a measured location point or surface of the machining tool according to a thermal hot spot in a thermal image, wherein positioning the machining tool comprises: cutting on a workpiece with the reference part as the reference part to establish the reference location point; cyclically approaching the workpiece with the machining tool and simultaneously monitoring thermal heating conditions of the machining tool; and if a thermal hot spot is monitored, completing positioning the measured location point by mechanical coordinate conversion.

2. The thermal image assisted machining method of claim 1, further comprising: using a tip of the reference part as the measured location point; tracking and offset cutting the workpiece with the measured location point and machining instructions; monitoring thermal heating conditions of the reference part to determine whether the workpiece size meets a tolerance standard; and determining whether to perform corrective machining on the workpiece according to the determination result. performing wear detection of the machining tool, comprising: tracking and moving on the workpiece with the reference part and the machining instructions and offsetting a distance from a cut surface of the workpiece; 3. The thermal image assisted machining method of claim 2, further comprising: simultaneously monitoring thermal heating conditions of the cut surface; if there is no thermal hot spot, determining that the wear amount of the machining tool is less than the tolerance standard; and if there is a thermal hot spot, determining that the wear amount of the machining tool is greater than the tolerance standard.

4. The thermal image assisted machining method of claim 3, wherein when it is determined that the wear amount of the machining tool is greater than the tolerance standard, further comprising: repositioning the machining tool by mechanical coordinate conversion to complete wear correction of the machining tool.

5. The thermal image assisted machining method of claim 3, wherein the tolerance is a difference allowed by a machining operator for a finished product size of a qualified workpiece.

6. A thermal image assisted machining method, comprising: establishing a reference location point or surface with a reference part; positioning a grinding wheel with the reference location point or surface; and determining a measured location point or surface of the grinding wheel according to a thermal hot spot in a thermal image, wherein positioning the grinding wheel comprises: dressing a surface of the grinding wheel with a tip of a dresser as the reference location point and simultaneously monitoring thermal heating conditions of the surface of the grinding wheel; and if a thermal hot spot is monitored, completing positioning the measured location surface by mechanical coordinate conversion. performing wear detection of the grinding wheel, comprising: tracking and moving on a workpiece with the grinding wheel and offsetting a distance from a grinding surface of the workpiece; simultaneously monitoring thermal heating conditions of the grinding surface; if there is no thermal hot spot, determining that the wear amount of the grinding wheel is less than a tolerance standard; and 7. The thermal image assisted machining method of claim 6, further comprising: if there is a thermal hot spot, determining that the wear amount of the grinding wheel is greater than the tolerance standard.

8. The thermal image assisted machining method of claim 7, wherein when it is determined that the wear amount of the grinding wheel is greater than the tolerance standard, further comprising: dressing the surface of the grinding wheel with the tip of the dresser as the measured location point and simultaneously monitoring thermal heating conditions of the surface of the grinding wheel; and if a thermal hot spot is monitored, repositioning the surface of the grinding wheel by mechanical coordinate conversion to complete wear correction of the grinding wheel.

9. The thermal image assisted machining method of claim 1, wherein the reference part is a tool bit.

10. The thermal image assisted machining method of claim 1, wherein the reference part is a tool holder. ​ ​ ​ 9. The thermal imaging-assisted processing method according to claim 1 or 6, used for measuring the angle of a blank, wherein at least two measured locations on the blank are obtained based on the at least two temperature-rising hot spots to calculate the tilt angle of the blank.

10. The thermal imaging assisted processing method according to claim 1 or 6, used for measuring the flatness of a blank, wherein at least three measured locations on the blank are obtained based on the at least three temperature-rising hot spots to calculate the flatness of the blank.

11. A thermal imaging-assisted processing device for positioning an object to be measured, the thermal imaging-assisted processing device comprising: A thermal imaging sensor module generates a thermal image to monitor the temperature rise of the object under test; as well as The processing unit includes a controller. The processing unit judges the thermal image. If the object to be measured generates a temperature rise hotspot, the controller performs mechanical coordinate conversion to obtain position coordinate information of the object to be measured, wherein the object to be measured includes a tool or a grinder. The tool or grinder cyclically approaches the surface of the blank and just contacts the blank surface. When the temperature rise hotspot is displayed, the processing unit performs the mechanical coordinate conversion to obtain the position coordinate information for locating the object to be measured and calculating the size of the object to be measured. 12 . The thermal imaging assisted processing device of claim 11 , wherein the processing unit obtains at least two position coordinate information through the mechanical coordinate conversion according to at least two temperature-rising hot spots of the object to be measured, so as to calculate the tilt angle of the object to be measured. 13 . The thermal imaging assisted processing device of claim 11 , wherein the processing unit obtains at least three position coordinate information through the mechanical coordinate conversion according to at least three temperature-rising hot spots of the object to be measured, so as to calculate the flatness of the object to be measured.

14. A thermal imaging assisted positioning device for positioning a cutting tool or a grinding tool, the thermal imaging assisted positioning device comprising: A thermal imaging sensor module monitors the temperature rise of the tool or the mold simultaneously; as well as The processing unit, when detecting at least one temperature rising hotspot of the tool or the grinding tool based on the thermal image, issues a prompt signal, wherein the prompt signal is at least one of a sound signal emitted by a speaker or a buzzer, a light signal emitted by a flash lamp or a light source, and an image signal generated by a screen.

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