Image processing apparatus, machine tool, and image processing method

Abstract

An image processing device (10) includes: a receiving unit (101) that receives a plurality of image data of a tool captured by an imaging unit installed in a device of a machine tool that machines a workpiece using the tool; a point group data forming unit (102) that forms point group data, which is outer contour information relating to the outer contour of the tool, on the basis of the plurality of pieces of image data received by the receiving unit; and an outer contour image forming unit (103) that forms outer contour image data indicating a two-dimensional or three-dimensional outer contour of the tool on the basis of the point group data.

Description

[0001] This application is a divisional application of the Chinese patent application with application number 202180008954.5, application date January 13, 2021, and name “Image processing device, machine tool and image processing method”. Technical Field

[0002] The invention relates to an image processing device, a machine tool and an image processing method. Background Art

[0003] When machining a workpiece using a machine tool, by understanding the shape and state of the tool, the workpiece can be machined correctly. Specifically, in machining with a machine tool, interference checking of tools is necessary, so it is important to understand the correct shape of the tool. In addition, by understanding the state of the tool, machining with good precision can be achieved. However, the current situation is that understanding the shape and state of the tool requires special work and time.

[0004] Patent document 1 discloses a technique for determining the replacement time of ultrasonic welding tools using images. Patent document 2 discloses a technique for managing tools of a grinding device using images. Patent document 3 discloses a technique for capturing the tip of a tool within a photographic field of view in response to a change in a tool of a machine tool. Patent document 4 discloses a technique for inspecting a tool installed on a machine tool by using an image.

[0005] Prior art literature

[0006] Patent Literature

[0007] Patent Document 1: Japanese Patent Application Publication No. 2010-207837

[0008] Patent Document 2: Japanese Patent Application Publication No. 2001-269844

[0009] Patent Document 3: Japanese Patent Application Laid-Open No. 9-323240

[0010] Patent Document 4: Japanese Patent Application Publication No. 2016-218550 Summary of the invention

[0011] However, according to any of the above patent documents, it is difficult to accurately grasp the shape and state of the tool.

[0012] Problems to be solved by the invention

[0013] The image processing device disclosed in the present invention comprises: a receiving unit, which receives multiple image data of a tool photographed by a camera unit, and the camera unit is installed on a machine tool that uses the tool to process a workpiece; a point group data forming unit, which forms contour information about the contour of the tool, namely point group data, based on the multiple image data received in the receiving unit; and a contour image forming unit, which forms contour image data representing the two-dimensional or three-dimensional contour of the tool based on the point group data.

[0014] In the present disclosure, in addition to the image processing apparatus, a machine tool, an image processing method, and the like are also provided.

[0015] These general and specific aspects may also be implemented by systems, methods, computer programs, and combinations thereof.

[0016] Effects of the Invention

[0017] According to the present invention, the shape and state of the tool can be accurately grasped. By being able to accurately grasp the shape and state of the tool, the workload of the machine tool can be reduced. In addition, the processing accuracy can be improved. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Figure 1 This is the appearance of the machine tool.

[0019] Figure 2 It is an explanatory diagram for explaining the positional relationship among a tool, an imaging unit, and an illumination unit of a machine tool according to the first embodiment.

[0020] Figure 3 This is a block diagram showing the structure of an image processing device according to the first embodiment.

[0021] Figure 4A This is an example of image data captured on a machine tool.

[0022] Figure 4B This is an example of point cloud data generated by an image processing device.

[0023] Figure 4C This is an example of outline image data generated by the image processing device.

[0024] Figure 5 This is a flowchart for explaining the processing of registering point cloud data according to the first embodiment.

[0025] Figure 6 This is a flowchart for explaining the processing of updating point cloud data according to the second embodiment.

[0026] Figure 7 This is a sequence diagram for explaining the process of updating outline information. DETAILED DESCRIPTION

[0027] Hereinafter, an image processing device, a machine tool, and an image processing method according to each embodiment will be described with reference to the accompanying drawings. In the following description, the same reference numerals are given to the same components and the description thereof will be omitted.

[0028] The "machine tool" described below is also referred to as a machine tool device, and processes a workpiece such as metal to be processed into a desired shape by cutting, grinding, etc. using a tool.

[0029] The "image processing device" of this embodiment is a device that processes images taken in a machine tool. In addition, it is used, for example, to manage tools used to process workpieces at a machine tool. Specifically, the image processing device acquires image data of the tool. And, based on the image data of the tool, the image processing device forms point group data and contour image data representing a two-dimensional or three-dimensional shape. Alternatively, the image processing device determines the contours of the tool such as the blade and shape based on the image data of the tool. Alternatively, the image processing device determines the boundary between the blade and the handle of the tool based on the image data of the tool. And, the image processing device can use them to control the position of the tool during processing and manage the tool.

[0030] The “point group data” is outline information for determining the outline of the tool, and is described as data of a point group formed by a plurality of points extracted from the outline of the tool image data. Furthermore, the point group data as the outline information of the tool can be associated with information related to each part of the tool, such as information determining the area of ​​the blade and the handle of the tool, the length of the tool, the outer diameter of the tool, and the outer diameter information corresponding to the position in the length direction of the tool.

[0031] "Outline image data" is used to represent the two-dimensional or three-dimensional shape and outline of a tool. For example, two-dimensional outline image data refers to a projection image representing the outline of a tool. In addition, three-dimensional outline image data refers to three-dimensional image data representing the shape of a tool, for example.

[0032] [Implementation Method 1]

[0033] <Machine Tools>

[0034] The machine tool 1 is, for example, Figure 1 The outer shape shown enables processing of the workpiece arranged in the processing area 200 .

[0035] Regarding the structure of the machine tool, use Figure 1 and Figure 2 The machine tool 1 comprises: a tool 11 mounted on a spindle and used for machining a workpiece; a holding unit 12 capable of holding the workpiece to be machined and capable of holding the workpiece by driving a driving mechanism; a camera unit 13 capable of photographing the tool and a lighting unit 14 capable of emitting light. Figure 1As shown, the machine tool 1 has a cover 201 that blocks a processing area 200 from the outside of the machine tool 1, and the cover 201 has a door 203 that can open and close an opening 202, and the opening 202 is used to take a workpiece to be processed from the processing area 200 to the outside of the machine tool 1. There is an operation panel 15 for performing operations such as processing of the machine tool 1.

[0036] In addition, machine tool 1 is used later Figure 3 In the present embodiment, the machine tool 1 and the image processing device 10 are separate devices and are connected via a wired cable or wireless communication. However, the present invention is not limited to this method, and the image processing device 10 may be built into the machine tool 1.

[0037] Tool 11 Figure 2 As shown in FIG. 1 , the machine tool 1 includes a blade 111 used when machining a workpiece, and a shank 112 held by a holder 114 of a spindle 113. Figure 1 The storage unit 16 shown as a storage unit stores a plurality of tools 11. Furthermore, the machine tool 1 can realize various types of processing by holding a plurality of selected tools 11 on the spindle 113. Figure 2 The structure shown is located at Figure 1 The dotted part in .

[0038] The spindle 113 holds the tool 11 used for machining, and is configured to be rotatable and movable by a control mechanism, etc. Thus, the machine tool 1 can machine a target workpiece.

[0039] The imaging unit 13 is, for example, a camera having an imaging element such as a CCD or a CMOS. The imaging unit 13 can capture the tool 11 mounted on the tool spindle 113 at a predetermined timing. The imaging unit 13 of this embodiment takes the tool 11 held by the tool spindle 113 as an imaging object. In addition, the imaging unit 13 may also take the workpiece held by the workpiece holding portion of the workpiece spindle as an imaging object. The imaging unit 13 may be disposed in a processing area within the machine tool 1. The imaging unit 13 may be fixed, for example, to an upper portion within the machine tool 1.

[0040] The camera unit 13 photographs the tool 11 mounted on the tool spindle 113 from multiple different directions. Specifically, the spindle 113 rotates the held tool 11 at a predetermined pitch, and the camera unit 13 photographs when the rotation of the tool 11 is stopped. At this time, the position or coordinates of the tool spindle 113 can be fixed. In addition, the position of the tool spindle 113 in the machine tool 1 is determined by taking the spindle direction as the coordinates in the Z-axis direction (X-axis, Y-axis and Z-axis). When the camera unit 13 is fixed to the upper part of the machine tool 1, the tool 11 is photographed from above. By photographing the tool 11 at predetermined pitch intervals in this way, the tool 11 can be photographed from multiple different directions even when the camera unit 13 is fixed. In addition, when the tool 11 cannot be accommodated in one image, the spindle 113 can move the tool 11 along the rotation axis.

[0041] The imaging unit 13 rotates the tool spindle 113 at a predetermined interval, and captures the tool 11 at the predetermined interval to obtain a plurality of images. That is, the entire image of the tool 11 can be obtained by dividing it into a plurality of images. Therefore, the imaging unit 13 obtains a plurality of image data observed from different directions for one tool 11. In addition, the imaging unit 13 outputs the obtained image data to the image processing device 10.

[0042] The imaging unit 13 can capture the tool 11 from a plurality of intersecting directions including a first direction intersecting (preferably orthogonal) with the rotation axis when the tool 11 is rotated, and a second direction different from the first direction. The first direction and the second direction may differ by 180 degrees (i.e., the first direction and the second direction may be opposite directions). The number of captured images may be, for example, two or more.

[0043] As described above, the machine tool 1 can obtain image data of the tool 11 from multiple directions by using the camera unit 13 to capture the tool 11 mounted on the tool spindle 113 of the machine tool 1. At this time, it is preferable that the camera unit 13 obtains a rotation image of the tool 11 at a predetermined pitch. That is, the camera unit 13 can capture an image every time the tool 11 is rotated around the rotation axis by n degrees (for example, 1≤n≤180) with the rotation axis of the spindle 113 as a reference. For example, 12 images can be captured every time the tool 11 is rotated around the rotation axis by 30 degrees, 20 images can be captured every time the tool 11 is rotated by 18 degrees, and 180 images can be captured every time the tool 11 is rotated by 2 degrees. In this way, for each tool 11, multiple images from different directions in the direction perpendicular to the rotation axis of the tool 11 can be obtained. Considering the capture time and the accuracy of the tool contour, it is preferable to capture 30 images (every time the rotation is n=12 degrees) to 60 images (every time the rotation is n=6 degrees), process these images, and form contour image data. At this time, the machine tool 1 supplies the image processing device 10 with information on the rotation angle of the tool 11 together with the image data. Thus, the image processing device 10 can generate point cloud data of three-dimensional information of the tool 11.

[0044] For example, the imaging unit 13 captures the tool 11 before storing the new tool 11 in the storage unit 16 of the machine tool 1. Thus, the machine tool 1 can easily generate model data of the tool 11 for interference checking in simulation before machining, and can effectively perform interference checking before machining.

[0045] The lighting unit 14 is as follows Figure 2 The configuration shown is such that the light emitting surface 141 is opposite to the light receiving surface 131 of the imaging unit 13, and the light emitted from the light emitting surface 141 that passes through the periphery of the tool is incident on the light receiving surface 131. Therefore, the illumination unit 14 is a transmissive illumination. By using the illumination unit 14 as a transmissive illumination, a projection image that can grasp the details of the contour of the tool 11 can be obtained. Thus, in the image processing device 10 that processes the projection image, correct point group data of the tool 11 can be obtained.

[0046] In addition, the camera unit 13 is arranged in a camera storage unit having a shutter for dividing the processing area except when photographing the tool 11. When photographing the tool 11, the shutter of the camera storage unit is opened, and the tool 11 mounted on the spindle in front of the camera unit 13 is moved by moving the spindle, and the tool 11 is photographed. It is preferable to calibrate the camera unit 13 before photographing the tool 11. An object whose distance from the camera unit 13 is known in advance is photographed, and it is confirmed based on the photographed image whether the distance to the object is consistent with the set value. If it is different, the position of the camera unit 13 is adjusted. As the object whose distance is known in advance, the back of the shutter can be used. In addition, it is also possible to detect whether foreign matter such as dust is attached to the light-transmitting components of the camera unit 13, namely the lens and glass, and the CMOS as a light-receiving element. Because if the foreign matter is captured in the camera image due to the attachment of foreign matter, it may be judged as cuttings in the judgment of AI. When the imaging unit 13 detects foreign matter, the control unit controls the light receiving element and the light transmitting member to vibrate using a vibration mechanism to make the foreign matter fall from the light transmitting member and the light receiving element, thereby obtaining an image with less foreign matter ingested. Thus, the chips can be accurately determined.

[0047] Depending on the purpose of photography, the positions of the camera unit 13 and the tool 11 are different. That is, the tool 11 is set at a predetermined position for photography in such a way that the portion for which the outline information of the tool 11 is desired to be generated enters the depth of field when the camera unit 13 is photographing. For example, if the "contour measurement" and "surface wear measurement" of the tool 11 are compared, in the case of the contour measurement of the tool 11, the contour portion is located on the working distance (WD) of the optical axis. On the other hand, in the case of the surface wear measurement of the tool 11, the center portion relative to the diameter of the tool 11 is located on the optical axis, and the outer surface of the tool 11 is located on the working distance (WD) of the optical axis. By photographing and acquiring images in this way, the desired image can be obtained.

[0048] <Image Processing Device>

[0049] use Figure 3 An example of an image processing device 10 according to the embodiment is described. The image processing device 10 includes a computing unit 100, a storage unit 110, an input unit 120, an output unit 130, and a communication unit 140. The image processing device 10 is, for example, an information processing device such as a personal computer or a tablet terminal. The image processing device 10 may be a structure included in the machine tool 1, or may be separated from the machine tool 1, and may perform wired communication or wireless communication. The input unit 120 and the display unit 130 may be a structure included in the image processing device 10 separated from the machine tool 1, or may be provided on the operation panel of the machine tool 1. Furthermore, the input unit 120 and the display unit 130 may be provided in the image processing device 10 and the machine tool 1, respectively, and the user may select and use any structure of the input unit 120 and the display unit 130.

[0050] The operation unit 100 is a controller that controls the entire image processing device 10. For example, the operation unit 100 reads and executes the control program P stored in the storage unit 110 to perform processing as the receiving unit 101, the point group data forming unit 102, the outline image forming unit 103, the setting unit 104, the storage processing unit 105, and the correction unit 106. In addition, the operation unit 100 is not limited to realizing the specified function through the cooperation of hardware and software, but can also be a hardware circuit designed specifically for realizing the specified function. That is, the operation unit 100 can be realized by various processors such as CPU, MPU, GPU, FPGA, DSP, ASIC, etc.

[0051] The storage unit 110 is a recording medium for recording various information. The storage unit 110 is implemented by, for example, a RAM, a ROM, a flash memory, an SSD (Solid State Device), a hard disk, other storage devices, or a suitable combination thereof. In addition to the control program P executed by the operation unit 100, the storage unit 110 also stores various data used by the machine tool 1. For example, the storage unit 110 stores image data D1, outline information D2, and outline image data D3.

[0052] The input unit 120 is an input unit such as a keyboard, a mouse, and a touch panel used for inputting data and operation signals, and the display unit 130 is an output unit such as a display used for outputting data.

[0053] The communication unit 140 is an interface circuit (module) for performing data communication with an external device (not shown). For example, the communication unit 140 can perform data communication with the imaging unit 13 that captures image data.

[0054] The receiving unit 101 receives a plurality of image data D1 of the tool 11 photographed by the imaging unit 13 installed in the machine tool 1 that processes the workpiece using the tool 11. For example, the receiving unit 101 receives the image data D1 of a plurality of projection images of the tool 11 photographed from different angles while rotating. The receiving unit 101 associates the received plurality of image data D1 with the identification information of the tool 11 and the identification information identifying the positional relationship between the tool 11 and the imaging unit 13 during the imaging, and stores them in the storage unit 110. Thereby, the point group data and the outline image data D3 related to the tool 11 as the object can be formed later.

[0055] Figure 4A is an example of the image data D1 received by the receiving unit 101. Figure 4AIn the example shown, the image data D1 includes the outer shape of the tool 11, and the tool 11 includes a blade 111 and a handle 112. The image data D1 may be acquired by one camera unit in one imaging. In addition, when receiving a plurality of image data captured simultaneously from a plurality of camera units 13 capturing different imaging ranges, the receiving unit 101 may synthesize the plurality of image data captured simultaneously into one image data D1. In addition, a plurality of images may be taken by one camera unit while the tool is moved, and the images may be synthesized into one image data D1.

[0056] The image data D1 may be an image including the entire tool 11 or an image including only the blade portion of the front end portion of the tool. In this case, a plurality of images may be acquired by automatically tracking the contour of the front end of the tool, and these images may be synthesized to acquire the image data D1 of the front end portion of the tool. In this way, when only the image of the front end portion of the tool is required, the image capturing time can be shortened.

[0057] In addition, the image data D1 may be displayed on the output unit 130 so that the operator can set the boundary between the blade of the tool 11 and the handle as other parts, which is automatically set by the input unit 120. For example, the operator may set Figure 4A (A) shown is set as the boundary between the blade and the handle. In addition, the image data D1 can also be displayed on the output unit 130 so that the operator can set the range of the object of processing such as analysis in the image processing device 10. For example, when the range of the analysis object is initially set to the blade below (A), the operator can change the setting from (A) to (B) as the range of the analysis object. Thus, the blade below (B) can be analyzed. By analyzing only a part of the blade, the analysis time can be shortened. Moreover, even when the analysis is performed in the same time, the number of analysis points can be increased. In this description, the setting of the boundary between the blade and the handle is described, but it can also be applied to settings such as setting the boundary between the tool and the tool holder.

[0058] The point group data forming unit 102 forms point group data related to the outer shape of the tool based on the multiple image data D1 received by the receiving unit 101. The multiple image data D1 include images of the tool 11 taken from two or more directions or multiple intersecting directions, wherein the directions include a first direction intersecting (preferably orthogonal) with the rotation axis of the tool 11, and a second direction different from the first direction. Specifically, the point group data forming unit 102 uses a point group composed of multiple points extracted from the contour of the tool 11 included in the multiple image data D1 obtained for one tool 11 as point group data. The point group data is formed using at least data obtained by processing the image of the tool 11 taken from the first direction and data obtained by processing the image of the tool 11 taken from the second direction. The photographic images required to form the outline image data do not need to be two, for example, they can also be 12 to 180, or 30 to 60. For example, the point group data forming unit 102 extracts points at a predetermined interval based on the contour of the tool 11 in each image data D1 obtained for one tool 11, and synthesizes the angle components of the extracted multiple points as point group data. The angle components are received from the machine tool 1 together with each image data D1. Thus, the point group data forming unit 102 can form point group data that can represent the three-dimensional structure of the tool 11. In addition, the point group data forming unit 102 stores the point group data formed based on the image data D1 as the outer contour information D2 together with the identification information of the tool 11 in the storage unit 110, or stores the outer contour information D2 in association with the identification information of the tool 11 in the tool management information. Figure 4B This is an example of point cloud data generated by the point cloud data generating unit 102 .

[0059] The outline image forming unit 103 forms outline image data D3 representing the two-dimensional or three-dimensional outline of the tool 11 based on the point group data. Specifically, the outline image forming unit 103 can use the outline of the plane obtained by cutting off a part of the three-dimensional structure formed based on the point group data as the outline image data D3. In addition, the outline image forming unit 103 can also use the outer shape of the three-dimensional structure formed based on the point group data of the outline information D2 as the outline image data D3. In addition, the outline image data D3 can also be two-dimensional data of the tool in a DXF format such as a two-dimensional CAD data format generated based on the outline information D2. In addition, the outline image forming unit 103 stores the outline image data D3 formed based on the point group data together with the identification information of the tool 11 in the storage unit 110. Figure 4C This is an example of outline image data D3 that three-dimensionally represents a tool formed by the outline image forming unit 103 .

[0060] The setting unit 104 sets the information of the blade 111 of the tool 11. Specifically, the setting unit 104 can set the area of ​​the blade 111 and the information related to the size such as the length and diameter of the blade 111 as the information of the blade 111, using the point group data of the outline information D2 or the outline image data D3 stored in the storage unit 110. Alternatively, the setting unit 104 can set the boundary between the blade 111 and the handle 112 of the tool 11 as the information of the blade 111. In addition, the setting unit 104 can also set both the area of ​​the blade 111 and the information related to the size and the boundary between the blade 111 and the handle 112 as the information of the blade 111.

[0061] For example, the setting unit 104 can set the area and size of the blade 111 of the tool 11 as the object or the boundary between the blade 111 and the handle 112 based on the point group data of the contour information D2 or the contour image data D3, with reference to data such as the shape of various types of tools 11, the shape of the blade 111, or the shape of the handle 112 that have been set in advance as a benchmark.

[0062] The storage processing unit 105 adds the information of the blade 111 set by the setting unit 104 to the outer contour information D2 as information of the tool 11, and stores it in the storage unit 110. Specifically, the storage processing unit 105 adds the information of the blade 111 to the outer contour information D2 of the target tool 11.

[0063] At this time, the correction unit 106 corrects the information of the blade 111 as needed. Specifically, the point group data formed by the point group data forming unit 102 or the outline image data D3 formed by the outline image forming unit 103 is displayed on the display as the output unit 130. The operator or the like can input a signal for correcting the information of the blade 111 with respect to these displayed data. For example, the correction unit 106 corrects the boundary position of the blade 111 and the handle 112 of the tool 11 as the information of the blade 111 based on the signal input by the operator or the like via the input unit 120. Alternatively, the correction unit 106 corrects the information of the blade 111 of the tool 11 based on the signal input by the operator or the like via the input unit 120. Thus, in the image processing device 10, the information of the blade 111 related to the tool 11 used in the machine tool 1 is registered in the outline information D2.

[0064] <Processing of Registration of Outline Information>

[0065] use Figure 5The flowchart shown in the figure explains the process of registering the outline information D2 of the image processing device 10 according to the first embodiment. When the machine tool 1 is in a timing where a new tool 11 is set on the spindle 113 and becomes usable, the process of registering the outline information D2 is started. Since the image is captured in a state where the tool 11 is mounted on the spindle 113, the position of the tool 11 can be accurately and easily controlled. First, the receiving unit 101 receives the image data D1 obtained by the camera unit 13 capturing the tool 11 mounted on the spindle 113, and stores it in the storage unit 110 (S01).

[0066] The point cloud data forming unit 102 uses the image data D1 of the tool 11 received in step S01 to form point cloud data consisting of a plurality of point clouds extracted from the outer shape of the tool 11 (S02). The point cloud data forming unit 102 stores the formed point cloud data in the storage unit 110 as outline information D2.

[0067] The outline image forming unit 103 forms outline image data D3 using the point cloud data of the tool 11 formed in step S02 ( S03 ) and stores the formed outline image data D3 in the storage unit 110 .

[0068] The setting unit 104 sets information of the blade 111 of the tool 11 using the point group data formed in step S02 or the outline image data D3 of the tool 11 formed in step S03 (S04). In addition, when the information of the blade 111 is set using the point group data, the formation of the outline image data D3 in step S03 can be omitted.

[0069] When correction related to the information of the blade 111 set in step S04 is necessary (S05: Yes), the correction unit 106 corrects the outline information D2 (S06). Specifically, when the operator inputs a signal via the input unit 120, the correction unit 106 corrects the outline information D2 based on the input signal.

[0070] The storage processing unit 105 additionally registers the information of the blade 111 set in step S04 or the information of the blade 111 corrected in step S06 to the outline information D2 stored in the storage unit 110 ( S07 ).

[0071] Thus, according to the image processing device 10 of the embodiment, when the machine tool 1 uses a new tool 11, the outline image data D3 and the outline information D2 can be easily and quickly generated. As a result, the machine tool 1 can use the outline image data D3 and the outline information D2 to perform interference inspection, and can easily realize high-precision workpiece processing.

[0072] [Implementation Method 2]

[0073] <Machine tool and image processing device>

[0074] The machine tool 1 and the image processing device 10 according to the first embodiment acquire an image and register the outline information D2 at a timing when a new tool 11 is available for use due to the new tool 11 being stored in the machine tool 1. On the other hand, the machine tool and the image processing device according to the second embodiment reacquire an image at a predetermined timing when the tool 11 for which the outline information D2 has been registered is worn or damaged due to use, and updates the outline information D2.

[0075] The machine tool of the second embodiment is used with Figure 1 and 2 The image processing device of the second embodiment is the same as the machine tool 1 described above and is used Figure 3 The image processing device 10 described above has the same structure, so refer to Figures 1 to 3 Provide explanation.

[0076] The camera unit 13 of the machine tool 1 according to the second embodiment captures images of the tools at predetermined intervals when the same tool is mounted on the spindle of the machine tool 1. Thus, the image processing device 10 compares the image data captured at a plurality of different timings, and can identify changes in the tool 11 such as wear. For example, the camera unit 13 may capture images of the tool 11 periodically at a timing when each tool 11 has been used a predetermined number of times. Alternatively, the camera unit 13 may capture images of the tool 11 when the value of any sensor at the machine tool 1 is outside a predetermined range.

[0077] Here, it is preferable that the position and posture of the imaging unit 13 are fixed at the timing of each imaging. In this case, by controlling the movement of the spindle 113 on which the tool 11 is mounted, fine focus adjustment during imaging can be performed. In this way, by fixing the imaging unit 13 and using the moving mechanism of the spindle 113, a moving mechanism is not required, and the size of the machine tool 1 can be prevented.

[0078] Furthermore, the correction unit 106 of the image processing device 10 of the second embodiment corrects the outline information D2 set based on the image data D1 of the tool 11 obtained in the previous imaging performed by the imaging unit 13, using the point group data formed based on the new image data D1 of the tool 11 obtained in the subsequent imaging. For example, the output unit 130 outputs the previous outline information D2 stored in the storage unit 110 to the output unit 130, and arranges and outputs the outline information D2 generated based on the newly obtained image data D1. Thus, it is easy for the operator to understand the change of the tool 11. The operator can compare these displayed data and input a signal for correcting the information of the blade part which is a part of the outline information D2. Alternatively, it is also possible to input a signal for correcting the wear of the tool in the tool management screen. The correction unit 106 corrects the outline information D2 and the information of the blade part included in the tool management information managed in the tool management screen according to the signal re-input by the operator via the input unit 120. Furthermore, the storage processing unit 105 registers the new outline information D2 corrected by the correction unit 106 in the storage unit 110. Thus, the state of the tool 11 is updated to the latest state based on the outline information D2. Furthermore, in the image processing device 10, when it is detected based on the updated new outline information D2 that the tool 11 is worn to the extent that it needs to be replaced, the output unit 130 can display a notification as a tool replacement timing.

[0079] <Processing of Updating Outline Information>

[0080] use Figure 6 The flowchart shown in the figure explains the process of updating the outline information D2 of the image processing device 10 according to Embodiment 1. First, the receiving unit 101 receives new image data D1 captured by the imaging unit 13 and stores it in the storage unit 110 (S11).

[0081] The point cloud data forming unit 102 forms new point cloud data using the new image data D1 of the tool 11 received in step S11 ( S12 ) and stores the newly formed point cloud data in the storage unit 110 as new outline information D2 .

[0082] The outline image forming unit 103 forms new outline image data D3 using the new point cloud data of the tool 11 formed in step S12 ( S13 ) and stores the formed new outline image data D3 in the storage unit 110 .

[0083] The setting unit 104 uses the new point group data formed in step S12 or the new outline image data D3 of the tool 11 formed in step S13 to set the information of the blade of the current tool 11 (S14). In addition, when the information of the blade 111 is set using the point group data, the formation of the new outline image data D3 in step S13 can also be omitted.

[0084] When the correction related to the blade information set in step S14 is required (S15: Yes), the correction unit 106 corrects the outer contour information D2 (S16). Specifically, when the operator inputs a signal via the input unit 120 with respect to the outer contour information D2 etc. displayed for comparison on the output unit 130, the correction unit 106 corrects the outer contour information D2 according to the input signal.

[0085] The storage processing unit 105 stores the new blade 111 information set in step S14 or the new blade 111 information corrected in step S16 in the storage unit 110 ( S17 ). Thus, the new outline information D2 obtained about the current state of the tool 11 is registered in the image processing device 10 .

[0086] Furthermore, when the current tool 11 in the state determined by the registered new outline information D2 has not reached the preset life of the tool 11 (S18: No), and the predetermined timing for acquiring new image data has arrived (S19: Yes), the image processing device 10 repeats the processing of steps S11 to S19. For example, in the image processing device 10, data for determining whether the life of the tool 11 has reached is stored in the storage unit 110.

[0087] On the other hand, when it is the timing to end the processing of the machine tool 1 ( S20 : ​​Yes), the processing of updating the outer contour information D2 is ended.

[0088] Furthermore, when the current tool 11 in the state determined by the registered new outline information D2 reaches the predetermined life of the tool 11 (S18: Yes), the image processing device 10 displays a notification (S21) as a timing for tool replacement on the output unit 130, and ends the processing of updating the outline information D2.

[0089] In addition, use Figure 7 The sequence diagram shown in the figure uses Figure 6 The processing of the machine tool 1 in the case of the processing of updating the outline information D2 described above will be described. First, the image processing device 10 sends a position control signal for adjusting the position of the tool 11 to the NC device 17 (S31). Thereby, the NC device 17 controls the spindle 113 and adjusts the position of the tool 11 (S32).

[0090] Then, the image processing device 10 transmits the lighting control signal S33 for dimming the lighting to the lighting unit 14 ( S33 ). As a result, the lighting unit 14 is dimmed ( S34 ).

[0091] Then, the image processing device 10 sends a photographing control signal to the imaging unit 13 ( S35 ). As a result, the imaging unit 13 photographs the image data D1 of the tool 11 ( S36 ). Then, the imaging unit 13 outputs the photographed image data D1 to the image processing device 10 .

[0092] The image processing device 10 uses the acquired image data D1 to Figure 6 Image processing and data updating are performed as described above (S38).

[0093] When the processing is continued, the image processing device 10 sends a new position control signal to the NC device 17 (S39). Then, the NC device 17 controls the spindle 113 and adjusts the position of the tool 11 (S40). Figure 7 The processing of steps S35 to S40 surrounded by the dotted line in FIG. 1 is performed until the processing of updating the outline information D2 is completed.

[0094] Alternatively, when the timing for replacing the tool 11 has arrived, the image processing device 10 sends a position control signal for controlling the position for replacement to the NC device 17 (S41). As a result, the NC device 17 controls the spindle 113 and adjusts it to the position for replacing the tool 11 (S42). Then, the tool 11 is replaced at the machine tool 1.

[0095] In this way, the new outline information D2 including changes in the tool such as wear and damage can be registered in the image processing device 10. Therefore, the machine tool 1 can use the new outline information D2 to reliably reflect the deterioration and deviation of the tool 11 such as wear and damage caused by long-term use, thereby preventing a decrease in machining accuracy.

[0096] [Modification 1]

[0097] The machine tool 1 of the first embodiment is described assuming that the imaging unit 13 captures a transmission image of the tool 11. In contrast, the imaging unit 13 may also capture reflected light. Specifically, the lighting unit 14 may be configured so that the light-emitting surface is oriented in the same direction as the light-receiving surface of the imaging unit 13, and the light emitted from the light-emitting surface illuminates the tool, and the reflected light thereof is incident on the light-receiving surface of the imaging unit 13. Thus, the imaging unit 13 can obtain an image of the surface of the tool 11, so that damage to the tool 11 can be reliably grasped.

[0098] [Modification 2]

[0099] In the above-mentioned machine tool 1 and image processing device 10, the acquired image data D1 is used for registration and update of the outline information D2. In contrast, it is also possible to use the acquired image data D1 in the image processing device 10 to identify the tool currently held by the holding unit 12 of the machine tool 1. In this case, the image processing device 10 stores tool list data, which is information on a plurality of tools that can be used in the machine tool 1, in the storage unit 110, and has a recognition unit that recognizes the tool in the calculation unit 100.

[0100] The tool list data includes, for example, the model of the tool as identification information of each tool. Furthermore, the tool list data includes at least the outer diameter and length of the blade of the tool as information related to the shape of the tool in each model. In addition, for tools with different outer diameters depending on the location of the blade 111 of the tool, information related to the length direction of the location of the tool can be included as information related to the shape of the tool. The recognition unit identifies the model of the tool mounted on the spindle 113 from the point group data or the contour image data D3 from the tool list data. In this way, the tool held on the spindle 113 can be easily identified.

[0101] [Variation 3]

[0102] In the above-mentioned image processing device 10, the setting unit 104 sets the information of the blade 111 of the tool 11. In contrast, the contour image forming unit 103 may set the information of the blade 111 using a learning model that has been learned in advance by machine learning. Specifically, the learning model applies parameters obtained by learning using teacher data, and the teacher data is composed of a collection of the contour image data of the tool, the boundary position of the blade 111 and the handle 112 obtained by actually measuring the tool 11, and the outer contour data of the shape obtained by actually measuring the tool 11. The learning model takes the image data of the tool 11 as input, and outputs the contour information D2 such as the boundary position of the blade 111 and the handle 112 of the tool 11 and the contour image data D3. Thus, the contour information D2 can be registered using the learning model.

[0103] As described above, the above embodiments have been described as examples of the technology disclosed in the present application, but the technology disclosed in the present application is not limited thereto, and can also be applied to embodiments in which changes, substitutions, additions, omissions, etc. are appropriately made.

[0104] By using the technology disclosed in this application, it is possible to automatically generate a 3D model of a tool for interference inspection. Furthermore, by using the technology disclosed in this application, it is possible to detect chip wrapping during tool replacement. Furthermore, by using the technology disclosed in this application, it is possible to automate tool calibration. Furthermore, by using the technology disclosed in this application, it is possible to detect notches on the front cutting edge and achieve quantitative tool management by measuring the wear amount on the back cutting edge.

[0105] The image processing device, machine tool, and image processing method described in all claims of the present disclosure are implemented by cooperation with hardware resources such as a processor, a memory, and a program.

[0106] Industrial Applicability

[0107] The image processing device, machine tool, and image processing method disclosed herein are used, for example, to facilitate interference inspection of a machine tool.

[0108] Description of symbols

[0109] 1 machine tool; 11 tool; 12 holding unit; 13 camera unit; 14 lighting unit; 10 image processing device; 100 operation unit; 101 receiving unit; 102 point group data forming unit; 103 outline image forming unit; 104 setting unit; 105 storage processing unit; 106 correction unit; 110 storage unit; 120 input unit; 130 output unit; 140 communication unit; D1 image data; D2 outline information; D3 outline image data; P control program.

Claims

1. A method for inspecting the state of a tool, wherein an image captured by a machine tool in which the tool is used to process a workpiece is processed, and the state of the tool is inspected while the tool is in the machine tool, the method comprising the following steps: In the first step, the front end of the tool is moved to the imaging unit while the tool is mounted on the spindle, and only the front end of the tool is imaged; In a second step, a contour is automatically traced from the front end of the tool to capture a plurality of images; A third step of analyzing the plurality of images to extract a plurality of points, and forming a point group data of the tool related to the outline of one of the tools by synthesizing the plurality of images captured in the second step; In a fourth step, the workpiece is machined with the tool mounted on the spindle, and after the machining, the front end of the tool is moved to the front of the camera unit with the tool still mounted on the spindle; A fifth step is to capture a plurality of images by automatically tracing the contour from the front end of the tool; and In the sixth step, the image captured in the fifth step is analyzed and compared with the point group data.

Images