Machining load determination system

Abstract

Provided is a system that improves the detection accuracy of a difference between a simulation and actual machining without limiting the accuracy of the simulation. This machining load determination system is provided with: an actual machining unit having a movable unit on which a tool or a workpiece is provided; a simulation unit having a virtual space including a virtual tool, a virtual workpiece, and a virtual movable unit; a virtual load acquisition unit that acquires virtual load information generated in the virtual movable unit; an actual load acquisition unit that acquires actual load information generated in the movable unit; and a load information determination unit that determines whether or not there is a difference between the virtual load information and the actual load information. The simulation unit calculates virtual load information and comparison site specifying data for specifying a comparison site between the virtual load information and the actual load information, and the virtual load acquisition unit acquires the virtual load information in association with the comparison site specifying data. The actual load acquisition unit acquires the actual load information in association with the comparison site identification data, and the load information determination unit compares the virtual load information with the actual load information on the basis of the comparison site identification data.

Description

Technical Field

[0001] The present disclosure relates to a machining load determination system. Background Art

[0002] There is an industrial machine (such as a machine tool, an electric discharge machine, etc.) having a movable part on which a tool or a workpiece is provided, and the industrial machine processes the workpiece by relatively moving the tool and the workpiece. In such an industrial machine, there is a technology for performing machining simulation using a virtual space obtained by reproducing the same environment as the actual machining environment through a three-dimensional model, and confirming whether there is a problem in the operation data (such as a machining program).

[0003] In such a technology, unexpected differences may occur between the three-dimensional model of the virtual space defined for simulation and the actual environment due to various factors. Examples of the various factors include the fact that the workpiece floats during machining in the actual environment and the fact that the wear correction of the tool is forgotten to be reflected in the three-dimensional model of the virtual space. In this case, a difference may occur between the result obtained by simulation and the result obtained in actual machining.

[0004] In this regard, Patent Document 1 discloses a technique in which a real machine part and a simulation part are arranged in parallel, the same instruction is input to the real machine part and the simulation part, the internal state quantity of the real machine part is compared with the internal state quantity of the simulation part, and the internal state quantity comparison value is compared with a pre-set detection threshold value to detect the contact / collision between the movable part and other objects. Through this technique, it is believed that it is possible to detect whether there is a difference between the result obtained by simulation and the result obtained in actual processing. In addition, Patent Document 1 discloses that the calculation formula of the model of the simulation part is simple and the processing time is short.

[0005] Prior art literature

[0006] Patent Literature

[0007] Patent Document 1: Japanese Patent Application Publication No. 2004-364396 Summary of the invention

[0008] Problem that the invention aims to solve

[0009] In the technology disclosed in Patent Document 1, it is necessary to simulate the simulation part in real time according to the operation of the real machine part. The processing time of using a three-dimensional model as a simulation of a virtual space is relatively long. Therefore, in the technology disclosed in Patent Document 1, as described above, the calculation formula of the model of the simulation part is simplified, and the processing time is shortened according to the operation time of the real machine part.

[0010] As described above, in real-time simulation of actual machining, the accuracy of the simulation is limited. As a result, the difference between the simulation and the actual machining may not be accurately detected.

[0011] Therefore, it is desirable to improve the accuracy of detecting the difference between the simulation and the actual processing without limiting the accuracy of the simulation.

[0012] Solutions for solving problems

[0013] The processing load determination system disclosed in the present invention comprises: an actual processing unit having a movable unit on which a tool or a workpiece is arranged, and the actual processing unit processes the workpiece by relatively moving the tool and the workpiece based on operation data; a simulation unit, which performs processing simulation of the virtual workpiece by relatively moving the virtual tool and the virtual workpiece based on the operation data in a virtual space including a virtual tool corresponding to the tool, a virtual workpiece corresponding to the workpiece, and a virtual movable unit corresponding to the movable unit; a virtual load acquisition unit, which acquires virtual load information generated on the virtual movable unit obtained by processing simulation by the simulation unit; an actual load acquisition unit, which acquires actual load information generated on the movable unit obtained by processing by the actual processing unit; and a load information determination unit, which compares the virtual load information with the actual load information to determine whether there is a difference between these information. The simulation unit calculates the virtual load information and comparison location determination data, the comparison location determination data is used to determine the comparison location between the virtual load information and the actual load information, the virtual load acquisition unit acquires the virtual load information in a manner associated with the comparison location determination data, the actual load acquisition unit acquires the actual load information in a manner associated with the comparison location determination data, and the load information determination unit compares the virtual load information with the actual load information based on the comparison location determination data. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] Figure 1 It is a diagram showing an overview of the industrial machine system according to the present embodiment.

[0015] Figure 2 It is a diagram showing the configuration of a machining load determination system according to the present embodiment.

[0016] Figure 3A It is a diagram showing an example of virtual load information and comparison location identification data.

[0017] Figure 3B It is a diagram showing an example of actual load information and comparison location identification data.

[0018] Figure 4A It is a diagram showing Example 1 of the machining load determination process performed by the machining load determination system according to the present embodiment (a case where there is no difference between the actual machining portion and the simulation portion).

[0019] Figure 4B It is a diagram showing Example 1 of the machining load determination process performed by the machining load determination system according to the present embodiment (a case where there is a difference between the actual machining portion and the simulation portion: an example in which contact is detected only in the simulation portion).

[0020] Figure 4C It is a diagram showing Example 1 of the machining load determination process performed by the machining load determination system according to the present embodiment (a case where there is a difference between the actual machining portion and the simulation portion: an example in which contact is detected only in the actual machining portion).

[0021] Figure 4D It is a diagram showing Example 1 of the machining load determination process performed by the machining load determination system according to the present embodiment (a case where there is a difference between the actual machining portion and the simulation portion: an example in which lift of the workpiece occurs).

[0022] Figure 5A It is a diagram showing Example 2 of the machining load determination process performed by the machining load determination system according to the present embodiment (a case where there is no difference between the actual machining portion and the simulation portion).

[0023] Figure 5B It is a diagram showing Example 2 of the machining load determination process performed by the machining load determination system according to the present embodiment (a case where there is a difference between the actual machining portion and the simulation portion: an example in which contact is detected only in the simulation portion).

[0024] Figure 5C It is a diagram showing Example 2 of the machining load determination process performed by the machining load determination system according to the present embodiment (a case where there is a difference between the actual machining portion and the simulation portion: an example in which contact is detected only in the actual machining portion).

[0025] Fig. 6A It is a diagram showing Example 3 of the machining load determination process performed by the machining load determination system according to the present embodiment (a case where there is no difference between the actual machining portion and the simulation portion).

[0026] Figure 6B It is a diagram showing Example 3 of the machining load determination process performed by the machining load determination system according to the present embodiment (a case where there is a difference between the actual machining portion and the simulation portion: an example in which contact is detected only in the simulation portion).

[0027] Figure 6CIt is a diagram showing Example 3 of the machining load determination process performed by the machining load determination system according to the present embodiment (a case where there is a difference between the actual machining portion and the simulation portion: an example in which contact is detected only in the actual machining portion).

[0028] Figure 7 It is a diagram showing Example 4 of the machining load determination process performed by the machining load determination system according to the present embodiment.

[0029] Figure 8 It is a diagram showing Example 5 of the machining load determination process performed by the machining load determination system according to the present embodiment. DETAILED DESCRIPTION

[0030] Hereinafter, an example of the present embodiment will be described with reference to the drawings. In addition, the same reference numerals are given to the same or corresponding parts in each drawing.

[0031] [Overview of Industrial Machinery Systems]

[0032] First, an overview of an industrial machine system according to the present embodiment will be described. Figure 1 1 is a diagram showing an overview of an industrial machine system according to the present embodiment. Figure 1 As shown, the industrial machine system 100 includes a numerical controller 110 , a drive unit 120 , and a machine tool (industrial machine) 130 .

[0033] The machine tool 130 is an actual processing unit described later, and performs removal processing on the workpiece W by relatively moving the tool T and the workpiece (processed object) W based on the operation data. Below, a machine of the M system (machining center system) is exemplified as a machine tool, but the present embodiment is not limited to this. The present embodiment can also be applied to a machine tool of the T system (lathe system). In addition, below, a machine tool is exemplified as an industrial machine, but the present embodiment is not limited to this. The present embodiment can also be applied to various industrial machines, such as an electric discharge machine, in which the tool T contacts the workpiece W to process the workpiece W.

[0034] The machine tool 130 includes a motor 132 , a tool mounting portion 134 , and a table 136 . The mounting portion 134 or the table 136 is a movable portion, and the tool T is mounted on the mounting portion 134 , and the workpiece W is placed on the table 136 .

[0035] The motor 132 is a motor of the movable part of the mounting part 134 or the worktable 136 , that is, a motor for feeding the tool T or the workpiece W, and may include, for example, a plurality of motors for X-axis movement, Y-axis movement, and Z-axis movement. The motor 132 is driven by the driving part 120 .

[0036] The numerical control device 110 generates a position command along a relative movement path of the tool T with respect to the workpiece W in the machine tool 130 based on the machining program.

[0037] The drive unit 120 drives the motor 132 in the machine tool 130 based on the position command from the numerical controller 110. The drive unit 120 may include a plurality of drive units for each motor (e.g., an X-axis motor, a Y-axis motor, and a Z-axis motor) of the machine tool 130. The drive unit 120 is, for example, a servo control unit, and performs drive control of the motor 132 based on the position command and position feedback detected by an encoder provided on the motor 132.

[0038] [Machining load judgment system]

[0039] Figure 2 FIG. 2 is a diagram showing the structure of a machining load determination system according to the present embodiment. Figure 2 As shown, the machining load determination system 10 includes an actual machining unit 12 , a simulation unit 14 , an actual load acquisition unit 16 , a virtual load acquisition unit 18 , a storage unit 20 , a load information determination unit 22 , an operation control unit 24 , a correction unit 26 , and a display unit 28 .

[0040] The actual processing unit 12 is the above-mentioned machine tool 130. As described above, the actual processing unit 12 uses a mounting unit 134 on which a tool T is installed or a table 136 on which a workpiece W is installed as a movable unit, and processes the workpiece W by relatively moving the tool T and the workpiece W based on operation data.

[0041] The simulation unit 14 may be provided in the numerical control device 110 described above, or may be composed of a computer different from the numerical control device 110. For example, as described later Figure 4A As shown, the simulation unit 14 has a virtual space VS, which includes a virtual tool Ts, a virtual workpiece Ws, a virtual mounting portion (virtual movable portion) 134s, and a workbench (virtual movable portion) 136s obtained by respectively simulating the tool T, the workpiece W, the mounting portion (movable portion) 134, and the workbench (movable portion) 136 in the actual processing unit 12. The simulation unit 14 performs a processing simulation of the virtual workpiece Ws by relatively moving the virtual tool Ts and the virtual workpiece Ws in the virtual space VS based on the operation data. The simulation unit 14 calculates Figure 3A The virtual load information generated in the virtual movable parts 134s and 136s and the comparison location identification data for identifying the comparison location between the virtual load information and the actual load information are shown. The details of the virtual load information and the comparison location identification data will be described later.

[0042] The actual load acquisition unit 16 is provided in the above-mentioned drive unit (servo control unit) 120. The actual load acquisition unit 16 acquires Figure 3B The actual load information generated on the movable parts 134 and 136 by the actual processing unit 12 is shown. Specifically, the actual load acquisition unit 16 acquires the virtual load information in a manner associated with the comparison part identification data. The details of the actual load information and the comparison part identification data will be described later.

[0043] The virtual load acquisition unit 18 may be provided in the numerical control device 110 or in a computer constituting the simulation unit 14, or may be formed by a computer different from the numerical control device 110 and the simulation unit 14. Figure 3A The virtual load information generated on the virtual movable parts 134s and 136s is obtained by the machining simulation performed by the simulation unit 14. Specifically, the virtual load acquisition unit 18 acquires the virtual load information in a manner associated with the comparison part identification data.

[0044] The load information determination unit 22 may be provided in the numerical control device 110 described above, or may be provided in the drive unit (servo control unit) 120, or may be composed of a computer different from the numerical control device 110 and the drive unit 120. The load information determination unit 22 compares the virtual load information with the actual load information based on the comparison position identification data to determine whether there is a difference between these information. That is, the load information determination unit 22 determines whether there is a difference between the load information of the movable parts 134 and 136 in the actual processing unit 12 and the load information of the virtual movable parts 134s and 136s in the simulation unit 14.

[0045] The motion control unit 24 is provided in the above-mentioned drive unit (servo control unit) 130. When the load information determination unit 22 determines that there is a difference between the virtual load information and the actual load information, the motion control unit 24 performs at least one of output limitation (for example, torque limitation) for moving the movable parts 134 and 136 in the actual processing unit 12, retreating (retracting) the movable parts 134 and 136 set in advance in the processing program, or immediately decelerating and stopping the movement of the movable parts 134 and 136.

[0046] The correction unit 26 may be provided in the numerical control device 110 described above, or may be constituted by a computer different from the numerical control device 110. When the load information determination unit 22 determines that there is a difference between the virtual load information and the actual load information, the correction unit 26 changes (corrects) the preconditions of the machining simulation in the simulation unit 14, for example, the preconditions related to the virtual tool Ts, the virtual workpiece Ws, and the virtual movable parts 134s and 136s in the operation data.

[0047] The above-mentioned simulation unit 14, actual load acquisition unit 16, virtual load acquisition unit 18, load information determination unit 22, action control unit 24 and correction unit 26 are composed of arithmetic processors such as CPU (Central Processing Unit), DSP (Digital Signal Processor), FPGA (Field-Programmable Gate Array) and the like. The various functions of the simulation unit 14, actual load acquisition unit 16, virtual load acquisition unit 18, load information determination unit 22, action control unit 24 and correction unit 26 are realized by executing predetermined software (program) stored in the storage unit 20, for example. The various functions of the simulation unit 14, actual load acquisition unit 16, virtual load acquisition unit 18, load information determination unit 22, action control unit 24 and correction unit 26 can also be realized by the cooperation of hardware and software, or can be realized only by hardware (electronic circuit).

[0048] The storage unit 20 is composed of a memory such as a ROM (Read Only Memory), a HDD (Hard Disk Drive), or a SSD (Solid State Drive). The storage unit 20 stores predetermined software (programs) for realizing various functions of the simulation unit 14, the actual load acquisition unit 16, the virtual load acquisition unit 18, the load information determination unit 22, the operation control unit 24, and the correction unit 26. In addition, the storage unit 20 stores the data acquired by the virtual load acquisition unit 18. Figure 3A The virtual load information and comparison location identification data shown in FIG. 1 and the actual load acquisition unit 16 acquire the virtual load information and comparison location identification data. Figure 3B Actual load information and comparative location determination data are shown.

[0049] The display unit 28 is composed of, for example, a liquid crystal display or an organic EL display. The display unit 28 displays the comparison location determination data determined by the load information determination unit 22 as having a difference between the virtual load information and the actual load information in a display method different from that of the difference. For example, the display unit 28 emphasizes and displays the block corresponding to the comparison location determination data determined as having a difference between the virtual load information and the actual load information in a program (operation data) in a display method different from that of the block without difference (e.g., color, blinking, etc.).

[0050] Next, refer to Figure 4A to Figure 8 Several examples of machining load determination processing performed by the above-described machining load determination system 10 will be described. Figure 4A to Figure 4D FIG. 1 is a diagram showing Example 1 of a machining load determination process performed by the machining load determination system according to the present embodiment. Figure 5A to Figure 5C FIG. 2 is a diagram showing a second embodiment of a machining load determination process performed by the machining load determination system according to the present embodiment. Figure 6A to Figure 6C It is a diagram showing Example 3 of the machining load determination process performed by the machining load determination system according to the present embodiment. Figure 7 FIG. 4 is a diagram showing a fourth embodiment of a machining load determination process performed by the machining load determination system according to the present embodiment. Figure 8 It is a diagram showing Example 5 of the machining load determination process performed by the machining load determination system according to the present embodiment.

[0051] [Example 1]

[0052] In the first embodiment, the elapsed time (time information) of program execution is used as comparison site identification data. Figure 4A 1 is a diagram showing a case where there is no difference between the actual load information of the movable part in the actual processing part and the virtual load information of the virtual movable part in the simulation part. Figure 4B This is a diagram showing a case where there is a difference between actual load information of a movable part in an actual machining part and virtual load information of a virtual movable part in a simulation part (an example in which contact is detected only in the simulation part). Figure 4C 1 is a diagram showing a case where there is a difference between actual load information of a movable part in an actual processing part and virtual load information of a virtual movable part in a simulation part (an example in which contact is detected only in the actual processing part). Figure 4D This is a diagram showing a case where there is a difference between actual load information of a movable part in an actual machining section and virtual load information of a virtual movable part in a simulation section (an example in which lifting of a workpiece occurs).

[0053] (When there is no difference between the actual processing part and the simulated part)

[0054] <1-1>

[0055] like Figure 4AAs shown, for example, the numerical control device 110 analyzes the machining program, creates time series data Xs(0), Xs(1) to Xs(n) of the machine coordinates Xs(i) of the virtual movable parts 134s and 136s from the start time Ts(0) to the time Ts(i) seconds later as operation data for the simulation unit 14, and outputs it to the simulation unit 14. In addition, for example, the numerical control device 110 analyzes the machining program, creates time series data Xr(0), Xr(1) to Xr(n) of the machine coordinates Xr(j) of the movable parts 134 and 136 from the start time Tr(0) to the time Tr(j) seconds later as operation data for the actual machining unit 12, and outputs it to the drive unit 120. Here, i and j are arbitrary integers from 1 to n. n is an integer greater than 1. Xs(i) and Xr(j) are q-dimensional arrays. The mechanical coordinates of the p-th axis of the virtual movable part are represented by Xsp(i), and the mechanical coordinates of the p-th axis of the movable part are represented by Xrp(j). q is an integer greater than 1, indicating the number of mechanical axes. p is an arbitrary integer from 1 to q.

[0056] In addition, in this embodiment, the numerical control device 110 analyzes the machining program and generates the time series data (operation data) of the machine coordinates. However, this embodiment is not limited to this, and the computer or other computer constituting the simulation unit 14 may analyze the machining program and generate the time series data (operation data) of the machine coordinates.

[0057] <1-2>

[0058] The simulation unit 14 performs machining simulation of the virtual workpiece Ws by relatively moving the virtual tool Ts and the virtual workpiece Ws based on the machine coordinates Xs(0) to Xs(n) (operation data) output from the numerical control device 110 .

[0059] The simulation unit 14 calculates contact information indicating whether the virtual tool Ts is in contact with the virtual workpiece Ws as virtual load information generated on the virtual movable part 134s, 136s at a certain machine coordinate Xs(i) at a certain time Ts(i). For example, the simulation unit 14 sets the contact flag to 0 when the virtual tool Ts is outside the virtual workpiece Ws, and sets the contact flag to 1 when the virtual tool Ts moves from the outside to the inside of the virtual workpiece Ws.

[0060] In addition, the simulation unit 14 calculates a certain time Ts(i) as comparison location determination data for determining a comparison location between the virtual load information and the actual load information. Specifically, the comparison location determination data is data that corresponds the time series or processing position of the virtual load information and the actual load information. More specifically, the comparison location determination data is data that makes a one-to-one correspondence between the time Ts(i) when the virtual tool Ts contacts the virtual workpiece Ws in the simulation unit 14 and the time Tr(j) when the tool T contacts the workpiece W in the actual processing unit 12. That is, the comparison location determination data is data that determines the time Ts(i) and the time Tr(j) as the comparison location between the virtual load information and the actual load information. Thus, the load information determination unit 22 can appropriately compare the virtual load information at the time Ts(i) and the actual load information at the time Tr(j) based on the comparison location determination data.

[0061] Furthermore, as described above, the simulation unit 14 may be provided in the numerical control device 110 , or may be constituted by a computer different from the numerical control device 110 .

[0062] The numerical control device 110 (virtual load acquisition unit 18) is as follows Figure 4A As shown, the contact flag 0 / 1 (virtual load information) is acquired in association with the time Ts(i) (comparison site identification data).

[0063] The simulation unit 14 performs the above-mentioned machining simulation before the actual machining unit 12 operates based on the operation data to pre-calculate the virtual load information and the comparison location determination data. In addition, the virtual load acquisition unit 18 may acquire the virtual load information in advance in a manner associated with the comparison location determination data and temporarily store it in the storage unit 20 before the actual machining unit 12 operates based on the operation data.

[0064] <1-3>

[0065] The driving unit 120 drives the motor 132 and movable parts 134 and 136 of the actual processing unit 12 based on the machine coordinates Xr(0) to Xr(n) (operation data) output from the numerical controller 110. Thus, the actual processing unit 12 processes the workpiece W by moving the tool T and the workpiece W relative to each other.

[0066] The drive unit 120 (actual load acquisition unit 16) acquires contact information indicating whether the tool T is in contact with the workpiece W as load information generated on the movable parts 134 and 136 at a certain machine coordinate Xr(j) at a certain time Tr(j). For example, the drive unit 120 (actual load acquisition unit 16) monitors the output (command or feedback information) of the motor 132, and when the output of the motor 132 exceeds a certain threshold, it is determined that the tool T is in contact with the workpiece W, and a contact signal is output to the numerical controller 110.

[0067] The driving unit 120 (actual load acquisition unit 16 ) acquires the contact signal (actual load information) in association with the time Tr(j) (comparison site identification data).

[0068] <1-4>

[0069] The numerical control device 110 (load information determination unit 22) compares the contact signal (actual load information) with the contact flag (virtual load information) based on the time Tr(j) and Ts(i) (comparison position determination data) to determine whether there is a difference between these information. Figure 4A In the example, the numerical control device 110 (load information determination unit 22) obtains a contact signal (actual load information) between time Ts(i-1) and Ts(i) based on time Tr(j) and Ts(i) (comparison location determination data), and the contact flag (virtual load information) at this time is 1, so it is determined that there is no difference in this information.

[0070] The load information determination unit 22 performs the above determination in real time while the actual processing unit 12 is operating, based on the virtual load information obtained in advance by the simulation unit 14 and the actual load information obtained in real time by the actual processing unit 12 .

[0071] The load information determination unit 22 may extract and compare only the virtual load information and the actual load information of a certain specific section in the comparison location identification data.

[0072] When there is no difference between the actual load information and the virtual load information, the numerical controller 110 (operation control unit 24 ) does not perform operation restriction.

[0073] As described above, the load information determination unit 22 may be provided in the numerical controller 110 or the drive unit 120 (servo control unit, amplifier), or may be composed of a computer different from the numerical controller 110 and the drive unit 120 .

[0074] When the load information determination unit 22 is arranged in the driving unit 120 (servo control unit, amplifier), the load information determination unit 22 can also calculate the moment Tr(j) when the contact signal is detected in the actual processing unit 12 on the driving unit 120 side. When this moment Tr(j) and the moments Ts(i-1) and Ts(i) when the contact flag changes from 0 to 1 in the simulation unit 14 satisfy the following equation, it is determined that there is no difference between the actual load information and the virtual load information.

[0075] Ts(i-1)≤Tr(j)≤Ts(i)

[0076] Generally, the acquisition cycle of the position of the movable part in the actual processing part is shorter than the simulation cycle, so the error (delay time) of the time Tr(j) when the contact signal is detected in the actual processing part 12 can be ignored. However, when the error (delay time) of the actual processing part is smaller than the error of the simulation part 14, the load information determination part 22 may determine that there is no difference between the actual load information and the virtual load information when there is a time Ts(i) when the contact flag becomes 1 in the simulation part 14 between the time Tr(j-1) and Tr(j) in the actual processing part 12.

[0077] In addition, the load information determination unit 22 may determine that there is no difference between the actual load information and the virtual load information based on the following determination using the contact position in addition to the determination based on the contact time described above. For example, the load information determination unit 22 may determine that there is no difference between the actual load information and the virtual load information when the machine coordinate Xr(j) where the contact signal is detected in the actual processing unit 12 and the machine coordinates Xs(i-1) and Xs(i) where the contact flag changes from 0 to 1 in the simulation unit 14 satisfy the following equation for all axes p operating between i-1 and i.

[0078] |Xrp(j)-Xsp(i)|≤|Xsp(i)-Xsp(i-1)|

[0079] This makes it possible to exclude the situation where the contact times (collision times) are exactly the same as a result of erroneous superposition.

[0080] (When there is a difference between the actual processing part and the simulation part) (Example where contact is detected only in the simulation part)

[0081] <1-1>

[0082] like Figure 4B As shown, for example, the numerical control device 110 creates time series data Xs(0), Xs(1) to Xs(n) of the machine coordinates Xs(i) of the virtual movable parts 134s and 136s from the start time Ts(0) to the time Ts(i) seconds later as the operation data for the simulation unit 14. Also, for example, the numerical control device 110 creates time series data Xr(0), Xr(1) to Xr(n) of the machine coordinates Xr(j) of the movable parts 134 and 136 from the start time Tr(0) to the time Tr(j) seconds later as the operation data for the actual processing unit 12 as the operation data.

[0083] <1-2>

[0084] As described above, the simulation unit 14 performs a machining simulation of the virtual workpiece Ws, and the numerical control device 110 (virtual load acquisition unit 18) performs a machining simulation of the virtual workpiece Ws. Figure 4BAs shown, the contact flag 0 / 1 (virtual load information) is acquired in association with the time Ts(i) (comparison site identification data).

[0085] <1-3>

[0086] As described above, the drive unit 120 and the actual processing unit 12 process the workpiece W, and the drive unit 120 (actual load acquisition unit 16) acquires the contact signal (actual load information) in a manner associated with the time Tr(j) (comparison position determination data). Figure 4B In the example, if the tool T is not in contact with the workpiece W due to damage or installation error of the tool, the drive unit 120 (actual load acquisition unit 16 ) does not acquire a contact signal and thus does not output a contact signal to the numerical controller 110 .

[0087] <1-4>

[0088] Similarly to the above, the numerical control device 110 (load information determination unit 22) compares the contact signal (actual load information) with the contact flag (virtual load information) based on the time Tr(j) and Ts(i) (comparison position determination data) to determine whether there is a difference between these information. Figure 4B In the example, the numerical control device 110 (load information determination unit 22) does not obtain a contact signal (actual load information) between time Ts(i-1) and Ts(i), and the contact flag (virtual load information) at this time is 1, so it is determined that there is a difference in these information.

[0089] When there is a difference between the actual load information and the virtual load information, the numerical control device 110 (motion control unit 24) decelerates and stops the machine tool 130. The numerical control device 110 (motion control unit 24) may also immediately stop the output of the motor, or may perform a predetermined emergency stop action. That is, the numerical control device 110 (motion control unit 24) performs output limitation for operating the movable parts 134 and 136, a predetermined retreat action of the movable parts 134 and 136, or an immediate deceleration and stop of the action of the movable parts 134 and 136 in the actual machining unit 12.

[0090] At this time, the operator of the machine tool can identify installation errors or damage of tool T by comparing the mechanical coordinates where contact (interference) was detected in the processing simulation and the mechanical coordinates where no contact (interference) was detected in the actual processing with the mechanical coordinates where contact (interference) was detected in the actual processing.

[0091] (When there is a difference between the actual processing part and the simulated part) (Example where contact is detected only in the actual processing part)

[0092] <1-1>

[0093] like Figure 4C As shown, for example, the numerical control device 110 creates time series data Xs(0), Xs(1) to Xs(n) of the machine coordinates Xs(i) of the virtual movable parts 134s and 136s from the start time Ts(0) to the time Ts(i) seconds later as the operation data for the simulation unit 14. Also, for example, the numerical control device 110 creates time series data Xr(0), Xr(1) to Xr(n) of the machine coordinates Xr(j) of the movable parts 134 and 136 from the start time Tr(0) to the time Tr(j) seconds later as the operation data for the actual processing unit 12 as the operation data.

[0094] <1-2>

[0095] As described above, the simulation unit 14 performs a machining simulation of the virtual workpiece Ws, and the numerical control device 110 (virtual load acquisition unit 18) performs a machining simulation of the virtual workpiece Ws. Figure 4A As shown in FIG. 1 , the contact flag 0 / 1 (virtual load information) is obtained in a manner associated with the time Ts(i) (comparison position determination data). Figure 4C In the simulation, at a certain machine coordinate Xs(i) at a certain time Ts(i), the virtual tool Ts does not move from the outside to the inside of the virtual workpiece Ws, and the simulation unit 14 sets the contact flag to 0.

[0096] <1-3>

[0097] As described above, the drive unit 120 and the actual machining unit 12 perform machining of the workpiece W, and the drive unit 120 (actual load acquisition unit 16 ) acquires the contact signal (actual load information) in association with the time Tr(j) (comparison location identification data).

[0098] <1-4>

[0099] Similarly to the above, the numerical control device 110 (load information determination unit 22) compares the contact signal (actual load information) with the contact flag (virtual load information) based on the time Tr(j) and Ts(i) (comparison position determination data) to determine whether there is a difference between these information. Figure 4B Although the contact flag (virtual load information) is not set between time Ts(i-1) and Ts(i), the contact signal (actual load information) is detected and acquired, and the numerical control device 110 (load information determination unit 22) determines that there is a difference in these information.

[0100] As described above, when there is a difference between the actual load information and the virtual load information, the numerical controller 110 (motion control unit 24 ) decelerates and stops the machine tool 130 .

[0101] (When there is a difference between the actual processing area and the simulated area) (Example of workpiece lifting)

[0102] <1-1>

[0103] like Figure 4C As shown, for example, the numerical control device 110 creates time series data Xs(0), Xs(1) to Xs(n) of the machine coordinates Xs(i) of the virtual movable parts 134s and 136s from the start time Ts(0) to Ts(i) seconds later as operation data for the simulation unit 14. Also, for example, the numerical control device 110 creates time series data Xr(0), Xr(1) to Xr(n) of the machine coordinates Xr(j) of the movable parts 134 and 136 from the start time Tr(0) to Tr(j) seconds later as operation data for the actual processing unit 12 as described above.

[0104] <1-2>

[0105] As described above, the simulation unit 14 performs a machining simulation of the virtual workpiece Ws, and the numerical control device 110 (virtual load acquisition unit 18) performs a machining simulation of the virtual workpiece Ws. Figure 4A As shown in FIG. 1 , the contact flag 0 / 1 (virtual load information) is acquired in a manner associated with the time Ts(i) (comparison position determination data). Figure 4D In the simulation, at a certain machine coordinate Xs(i) at a certain time Ts(i), the virtual tool Ts does not move from the outside to the inside of the virtual workpiece Ws, and the simulation unit 14 sets the contact flag to 0.

[0106] <1-3>

[0107] As described above, the drive unit 120 and the actual processing unit 12 process the workpiece W, and the drive unit 120 (actual load acquisition unit 16) acquires the contact signal (actual load information) in a manner associated with the time Tr(j) (comparison position determination data). Figure 4D In the case where the workpiece W floats from the table 136 due to chips or the like, or when the movable parts 134, 136 or the tool T floats, the tool T comes into contact with the workpiece W earlier than in the simulation, and the drive unit 120 (actual load acquisition unit 16) outputs a contact signal to the numerical controller 110 earlier than in the simulation. Alternatively, the tool T comes into contact with the workpiece W later than in the simulation, and the drive unit 120 (actual load acquisition unit 16) outputs a contact signal to the numerical controller 110 later than in the simulation.

[0108] <1-4>

[0109] Similarly to the above, the numerical control device 110 (load information determination unit 22) compares the contact signal (actual load information) with the contact flag (virtual load information) based on the time Tr(j) and Ts(i) (comparison position determination data) to determine whether there is a difference between these information. Figure 4D In the case where the tool T and the workpiece W come into contact earlier than in the simulation, the contact signal (actual load information) is detected and acquired between the time Ts(i-1) and Ts(i) even though the contact flag (virtual load information) is not set, and the numerical control device 110 (load information determination unit 22) determines that there is a difference in these information. Alternatively, when the tool T and the workpiece W come into contact later than in the simulation, the numerical control device 110 (load information determination unit 22) does not acquire the contact signal (actual load information) between the time Ts(i-1) and Ts(i), and the contact flag (virtual load information) at this time is 1, so it is determined that there is a difference in these information.

[0110] As described above, when there is a difference between the actual load information and the virtual load information, the numerical controller 110 (motion control unit 24 ) decelerates and stops the machine tool 130 .

[0111] [Example 2]

[0112] In Example 2, the machine coordinates (position information of the movable part) are used as the comparison position determination data. Thus, even when the time (delay) difference between the simulation and the actual processing is significant due to external factors of the machine tool, it is possible to accurately determine whether there is a difference between the actual load information and the virtual load information. Figure 5A 1 is a diagram showing a case where there is no difference between the actual load information of the movable part in the actual processing part and the virtual load information of the virtual movable part in the simulation part. Figure 5B This is a diagram showing a case where there is a difference between actual load information of a movable part in an actual machining part and virtual load information of a virtual movable part in a simulation part (an example in which contact is detected only in the simulation part). Figure 5C This is a diagram showing a case where there is a difference between actual load information of a movable part in an actual processing section and virtual load information of a virtual movable part in a simulation section (an example in which contact is detected only in the actual processing section).

[0113] (When there is no difference between the actual processing part and the simulated part)

[0114] <2-1>

[0115] like Figure 5AAs shown, for example, the numerical control device 110 analyzes the machining program, creates time series data Xs(0), Xs(1) to Xs(n) of the mechanical coordinates Xs(i) of the virtual movable parts 134s and 136s from the start time Ts(0) to the time Ts(i) seconds later as operation data for the simulation unit 14, and outputs it to the simulation unit 14. In addition, for example, the numerical control device 110 analyzes the machining program, creates time series data Xr(0), Xr(1) to Xr(n) of the mechanical coordinates Xr(j) of the movable parts 134 and 136 from the start time Tr(0) to the time Tr(j) seconds later as operation data for the actual machining unit 12, and outputs it to the drive unit 120. Here, i and j are arbitrary integers from 1 to n. n is an integer greater than 1.

[0116] In addition, in this embodiment, the numerical control device 110 analyzes the machining program and generates the time series data (operation data) of the machine coordinates. However, this embodiment is not limited to this, and the computer or other computer constituting the simulation unit 14 may analyze the machining program and generate the time series data (operation data) of the machine coordinates.

[0117] <2-2>

[0118] The simulation unit 14 performs machining simulation of the virtual workpiece Ws by relatively moving the virtual tool Ts and the virtual workpiece Ws based on the machine coordinates Xs(0) to Xs(n) (operation data) output from the numerical control device 110 .

[0119] The simulation unit 14 calculates contact information indicating whether the virtual tool Ts is in contact with the virtual workpiece Ws as virtual load information generated on the virtual movable part 134s, 136s at a certain machine coordinate Xs(i) at a certain time Ts(i). For example, the simulation unit 14 sets the contact flag to 0 when the virtual tool Ts is outside the virtual workpiece Ws, and sets the contact flag to 1 when the virtual tool Ts moves from the outside to the inside of the virtual workpiece Ws.

[0120] In addition, the simulation unit 14 calculates a certain machine coordinate Xs(i) at a certain time Ts(i) as comparison location determination data for determining a comparison location between the virtual load information and the actual load information. Specifically, the comparison location determination data is data that associates the time series or processing positions of the virtual load information with the actual load information. More specifically, the comparison location determination data is data that associates the machine coordinate Xs(i) where the virtual tool Ts contacts the virtual workpiece Ws in the simulation unit 14 with the machine coordinate Xr(j) where the tool T contacts the workpiece W in the actual processing unit 12. That is, the comparison location determination data is data that identifies the machine coordinate Xs(i) and the machine coordinate Xr(j) as comparison locations between the virtual load information and the actual load information. Thus, the load information determination unit 22 can appropriately compare the virtual load information of the machine coordinate Xs(i) and the actual load information of the machine coordinate Xr(j) based on the comparison location determination data.

[0121] Furthermore, as described above, the simulation unit 14 may be provided in the numerical control device 110 , or may be constituted by a computer different from the numerical control device 110 .

[0122] The numerical control device 110 (virtual load acquisition unit 18) is as follows Figure 5A As shown, the contact flag 0 / 1 (virtual load information) is acquired in a manner associated with the machine coordinate Xs(i) (comparison point identification data).

[0123] The simulation unit 14 performs the above-mentioned machining simulation before the actual machining unit 12 operates based on the operation data to pre-calculate the virtual load information and the comparison location determination data. In addition, the virtual load acquisition unit 18 may acquire the virtual load information in advance in a manner associated with the comparison location determination data and temporarily store it in the storage unit 20 before the actual machining unit 12 operates based on the operation data.

[0124] <2-3>

[0125] The driving unit 120 drives the motor 132 and movable parts 134 and 136 of the actual processing unit 12 based on the machine coordinates Xr(0) to Xr(n) (operation data) output from the numerical controller 110. Thus, the actual processing unit 12 processes the workpiece W by moving the tool T and the workpiece W relative to each other.

[0126] The drive unit 120 (actual load acquisition unit 16) acquires contact information indicating whether the tool T is in contact with the workpiece W as load information generated on the movable parts 134 and 136 at a certain machine coordinate Xr(j) at a certain time Tr(j). For example, the drive unit 120 (actual load acquisition unit 16) monitors the output (command or feedback information) of the motor 132, and when the output of the motor 132 exceeds a certain threshold, it is determined that the tool T is in contact with the workpiece W, and a contact signal is output to the numerical controller 110.

[0127] The driving unit 120 (actual load acquisition unit 16 ) acquires the contact signal (actual load information) in a manner associated with the machine coordinates Xr(j) (comparison site identification data).

[0128] <2-4>

[0129] The numerical control device 110 (load information determination unit 22) compares the contact signal (actual load information) with the contact flag (virtual load information) based on the machine coordinates Xr(j) and Xs(i) (comparison position determination data) to determine whether there is a difference between these information. Figure 5A In the numerical control device 110 (load information determination unit 22), based on the machine coordinates Xr(j) and Xs(i) (comparison position determination data), since the machine coordinates Xr(j) (comparison position determination data) where the contact signal (actual load information) is detected in the actual processing unit 12 and the machine coordinates Xs(i-1) and Xs(i) (comparison position determination data) where the contact flag (virtual load information) changes from 0 to 1 in the simulation unit 14 satisfy the following inequality for all axes p moving between i-1 and i, it is determined that there is no difference between the actual load information and the virtual load information.

[0130] |Xrp(j)-Xsp(i)|≤·Xsp(i)-Xsp(i-1)|

[0131] In addition, when there are multiple mechanical coordinates Xr(j) (comparison position determination data) in which a contact signal (actual load information) is detected in the actual processing unit 12 and mechanical coordinates Xs(i) (comparison position determination data) in which the contact mark (virtual load information) changes from 0 to 1 in the simulation unit 14, the above-mentioned judgment can also be performed according to the order of contact.

[0132] The load information determination unit 22 performs the above determination in real time while the actual processing unit 12 is operating, based on the virtual load information obtained in advance by the simulation unit 14 and the actual load information obtained in real time by the actual processing unit 12 .

[0133] The load information determination unit 22 may extract and compare only the virtual load information and the actual load information of a specific section in the comparison location identification data.

[0134] When there is no difference between the actual load information and the virtual load information, the numerical controller 110 (operation control unit 24 ) does not perform operation restriction.

[0135] As described above, the load information determination unit 22 may be provided in the numerical controller 110 or the drive unit 120 (servo control unit, amplifier), or may be composed of a computer different from the numerical controller 110 and the drive unit 120 .

[0136] (When there is a difference between the actual processing part and the simulation part) (Example where contact is detected only in the simulation part)

[0137] <2-1>

[0138] like Figure 5B As shown, for example, the numerical control device 110 creates time series data Xs(0), Xs(1) to Xs(n) of the machine coordinates Xs(i) of the virtual movable parts 134s and 136s from the start time Ts(0) to the time Ts(i) seconds later as the operation data for the simulation unit 14. Also, for example, the numerical control device 110 creates time series data Xr(0), Xr(1) to Xr(n) of the machine coordinates Xr(j) of the movable parts 134 and 136 from the start time Tr(0) to the time Tr(j) seconds later as the operation data for the actual processing unit 12 as the operation data.

[0139] <2-2>

[0140] As described above, the simulation unit 14 performs a machining simulation of the virtual workpiece Ws, and the numerical control device 110 (virtual load acquisition unit 18) performs a machining simulation of the virtual workpiece Ws. Figure 5B As shown, the contact flag 0 / 1 (virtual load information) is acquired in a manner associated with the machine coordinate Xs(i) (comparison point identification data).

[0141] <2-3>

[0142] As described above, the drive unit 120 and the actual processing unit 12 process the workpiece W, and the drive unit 120 (actual load acquisition unit 16) acquires the contact signal (actual load information) in a manner associated with the machine coordinates Xr(j) (comparison position identification data). Figure 5B In the example, if the tool T is not in contact with the workpiece W due to damage or installation error of the tool, the drive unit 120 (actual load acquisition unit 16 ) does not acquire a contact signal and thus does not output a contact signal to the numerical controller 110 .

[0143] In addition, when contact is detected at another location after machining has progressed to a certain extent, the drive unit 120 (actual load acquisition unit 16 ) may output a contact signal (actual load information) and machine coordinates Xr(k) (comparison location identification data) to the numerical control device 110 .

[0144] <2-4>

[0145] Similarly to the above, the numerical control device 110 (load information determination unit 22) compares the contact signal (actual load information) with the contact flag (virtual load information) based on the machine coordinates Xr(j) and Xs(i) (comparison position determination data) to determine whether there is a difference between these information. Figure 5B In the example, no contact signal (actual load information) is obtained in the actual processing unit 12, while the contact flag (virtual load information) 1 is present in the simulation unit 14, so the numerical control device 110 (load information determination unit 22) determines that there is a difference between these information. Alternatively, since the machine coordinates Xr(k) (comparison position determination data) where the contact signal (actual load information) is detected in the actual processing unit 12 and the machine coordinates Xs(i-1) and Xs(i) (comparison position determination data) where the contact flag (virtual load information) changes from 0 to 1 in the simulation unit 14 do not satisfy the following inequality for all axes p that operate between i-1 and i, the numerical control device 110 (load information determination unit 22) determines that there is a difference between the actual load information and the virtual load information.

[0146] |Xrp(k)-Xsp(i)|≤|Xsp(i)-Xsp(i-1)|

[0147] When there is a difference between the actual load information and the virtual load information, the numerical controller 110 (motion control unit 24) decelerates and stops the machine tool 130. The numerical controller 110 (motion control unit 24) can stop the output of the motor immediately or perform a predetermined emergency stop operation. That is, the numerical controller 110 (motion control unit 24) performs output limitation for operating the movable parts 134 and 136, a predetermined retreat operation of the movable parts 134 and 136, or an immediate deceleration and stop of the operation of the movable parts 134 and 136 in the actual machining unit 12.

[0148] At this time, the operator of the machine tool can identify installation errors or damage of tool T by comparing the mechanical coordinates where contact (interference) was detected in the processing simulation and where no contact (interference) was detected in the actual processing with the mechanical coordinates where contact (interference) was detected in the actual processing.

[0149] (When there is a difference between the actual processing part and the simulated part) (Example where contact is detected only in the actual processing part)

[0150] <2-1>

[0151] like Figure 5C As shown, for example, the numerical control device 110 creates time series data Xs(0), Xs(1) to Xs(n) of the machine coordinates Xs(i) of the virtual movable parts 134s and 136s from the start time Ts(0) to the time Ts(i) seconds later as the operation data for the simulation unit 14. Also, for example, the numerical control device 110 creates time series data Xr(0), Xr(1) to Xr(n) of the machine coordinates Xr(j) of the movable parts 134 and 136 from the start time Tr(0) to the time Tr(j) seconds later as the operation data for the actual processing unit 12 as the operation data.

[0152] <2-2>

[0153] As described above, the simulation unit 14 performs a machining simulation of the virtual workpiece Ws, and the numerical control device 110 (virtual load acquisition unit 18) performs a machining simulation of the virtual workpiece Ws. Figure 5B As shown in FIG. 1 , the contact flag 0 / 1 (virtual load information) is acquired in a manner associated with the machine coordinate Xs(i) (comparison position identification data). Figure 5C In the simulation, at a certain machine coordinate Xs(i) at a certain time Ts(i), the virtual tool Ts does not move from the outside to the inside of the virtual workpiece Ws, so the simulation unit 14 sets the contact flag to 0.

[0154] In addition, when contact is detected at other locations after processing has progressed to a certain extent, the numerical control device 110 (virtual load acquisition unit 18) may acquire the contact mark 1 (virtual load information) in a manner associated with the mechanical coordinates Xs(k) (comparison location determination data) where the contact was detected.

[0155] <2-3>

[0156] As described above, the drive unit 120 and the actual machining unit 12 perform machining of the workpiece W, and the drive unit 120 (actual load acquisition unit 16 ) acquires the contact signal (actual load information) in association with the machine coordinates Xr(j) (comparison location identification data).

[0157] <2-4>

[0158] Similarly to the above, the numerical control device 110 (load information determination unit 22) compares the contact signal (actual load information) with the contact flag (virtual load information) based on the machine coordinates Xr(j) and Xs(i) (comparison position determination data) to determine whether there is a difference between these information. Figure 5C In the case where the contact flag (virtual load information) is 0 at the machine coordinate Xs(i) (comparison location determination data) in the simulation unit 14 corresponding to the machine coordinate Xr(j) (comparison location determination data) at which the contact signal (actual load information) is detected in the actual machining unit 12, the numerical controller 110 (load information determination unit 22) determines that there is a difference between these information. Alternatively, since the machine coordinate Xr(j) (comparison location determination data) at which the contact signal (actual load information) is detected in the actual machining unit 12 and the machine coordinates Xs(k-1) and Xs(k) (comparison location determination data) at which the contact flag (virtual load information) changes from 0 to 1 in the simulation unit 14 do not satisfy the following inequality for all axes p operating between i-1 and i, the numerical controller 110 (load information determination unit 22) determines that there is a difference between the actual load information and the virtual load information.

[0159] |Xrp(j)-Xsp(k)|≤|Xsp(k)-Xsp(k-1)|

[0160] As described above, when there is a difference between the actual load information and the virtual load information, the numerical controller 110 (motion control unit 24 ) decelerates and stops the machine tool 130 .

[0161] [Example 3]

[0162] In Embodiment 3, the operation data is used as the comparison location identification data. By recording the machine coordinates in the operation data, it is easy to identify the problem location of the processing data. Fig. 6A 1 is a diagram showing a case where there is no difference between the actual load information of the movable part in the actual processing part and the virtual load information of the virtual movable part in the simulation part. Figure 6B This is a diagram showing a case where there is a difference between actual load information of a movable part in an actual machining part and virtual load information of a virtual movable part in a simulation part (an example in which contact is detected only in the simulation part). Figure 6C This is a diagram showing a case where there is a difference between actual load information of a movable part in an actual processing section and virtual load information of a virtual movable part in a simulation section (an example in which contact is detected only in the actual processing section).

[0163] (When there is no difference between the actual processing part and the simulated part)

[0164] <3-1>

[0165] like Fig. 6A As shown, for example, the simulation unit 14 analyzes the machining program, and creates time series data Xs(0), Xs(1) to Xs(n) of the mechanical coordinates Xs(i) of the virtual movable parts 134s and 136s from the start time Ts(0) to the time Ts(i) seconds later as operation data for the simulation unit 14. On the other hand, for example, the numerical control device 110 analyzes the machining program, and creates time series data Xr(0), Xr(1) to Xr(n) of the mechanical coordinates Xr(j) of the movable parts 134 and 136 from the start time Tr(0) to the time Tr(j) seconds later as operation data for the actual machining unit 12, and outputs it to the drive unit 120. Here, i and j are arbitrary integers from 1 to n. n is an integer greater than 1.

[0166] <3-2>

[0167] The simulation unit 14 performs machining simulation of the virtual workpiece Ws by relatively moving the virtual tool Ts and the virtual workpiece Ws based on the machine coordinates Xs(0) to Xs(n) (operation data).

[0168] As virtual load information generated in the virtual movable part 134s, 136s at a certain machine coordinate Xs(i) at a certain time Ts(i), the simulation unit 14 calculates contact information indicating whether the virtual tool Ts is in contact with the virtual workpiece Ws. In addition, the simulation unit 14 calculates a certain machine coordinate Xs(i) at a certain time Ts(i) as comparison location determination data for determining a comparison location between the virtual load information and the actual load information. For example, when the virtual tool Ts enters from the outside to the inside of the virtual workpiece Ws between the machine coordinates Xs(j-1) and Xs(j), the simulation unit 14 supplements the coordinates of the machine coordinate Xs(j) in the format of ", Ln X_Y_Z_" in association with the instruction block in the operation data. Here, n is an integer greater than 1, and when multiple contacts occur during one block, n is incremented and multiple are recorded.

[0169] In addition, when the operation data is a small line segment, the coordinates of the machine coordinates Xs(j) (virtual load information and comparison position determination data) can be supplemented in units of one block instead of in units of instruction blocks. In addition, the example of the case where the feed axis is three axes is shown, but the present embodiment can also be applied to the case where the feed axis is four or more axes.

[0170] The comparison location determination data is data that associates the virtual load information with the time series or processing position of the actual load information. More specifically, the comparison location determination data is data that associates the machine coordinate Xs(i) where the virtual tool Ts contacts the virtual workpiece Ws in the simulation unit 14 with the machine coordinate Xr(j) where the tool T contacts the workpiece W in the actual processing unit 12. That is, the comparison location determination data is data that identifies the machine coordinate Xs(i) and the machine coordinate Xr(j) as the comparison location of the virtual load information and the actual load information. Thus, the load information determination unit 22 can appropriately compare the virtual load information of the machine coordinate Xs(i) and the actual load information of the machine coordinate Xr(j) based on the comparison location determination data.

[0171] The numerical control device 110 (virtual load acquisition unit 18) acquires Fig. 6A As shown in the figure, ", Ln X_Y_Z_" (virtual load information and comparison location determination data) is added to the operation data.

[0172] The simulation unit 14 performs the above-mentioned machining simulation before the actual machining unit 12 operates based on the operation data to pre-calculate the virtual load information and the comparison location determination data. In addition, the virtual load acquisition unit 18 may acquire the virtual load information in advance in a manner associated with the comparison location determination data and temporarily store it in the storage unit 20 before the actual machining unit 12 operates based on the operation data.

[0173] <3-3>

[0174] The driving unit 120 drives the motor 132 and movable parts 134 and 136 of the actual processing unit 12 based on the machine coordinates Xr(0) to Xr(n) (operation data) output from the numerical controller 110. Thus, the actual processing unit 12 processes the workpiece W by moving the tool T and the workpiece W relative to each other.

[0175] The drive unit 120 (actual load acquisition unit 16) acquires contact information indicating whether the tool T is in contact with the workpiece W as load information generated on the movable parts 134 and 136 at a certain machine coordinate Xr(j) at a certain time Tr(j). For example, the drive unit 120 (actual load acquisition unit 16) monitors the output (command or feedback information) of the motor 132, and when the output of the motor 132 exceeds a certain threshold, it is determined that the tool T is in contact with the workpiece W, and a contact signal is output to the numerical controller 110.

[0176] The driving unit 120 (actual load acquisition unit 16 ) acquires the contact signal (actual load information) in a manner associated with the machine coordinates Xr(j) (comparison site identification data).

[0177] <3-4>

[0178] The numerical control device 110 (load information determination unit 22) compares the contact signal (actual load information) with the presence or absence of contact (virtual load information) based on the machine coordinates Xr(j) and Xs(i) (comparison position determination data) to determine whether there is a difference between these information. Fig. 6A In the figure, since the mechanical coordinates Xr(j) (comparison position determination data) of the contact signal (actual load information) detected in the actual processing unit 12 and the mechanical coordinates Xs(i) (comparison position determination data) represented by ", Ln X_Y_Z_" added to the operation data in the simulation unit 14 satisfy the following inequality for all axes p moving between i-1 and i, the numerical control device 110 (load information determination unit 22) determines that there is no difference between the actual load information and the virtual load information.

[0179] |Xrp(j)-Xsp(i)|≤|Xsp(i)-Xsp(i-1)|

[0180] When a plurality of “, Ln X_Y_Z_” (virtual load information and comparison location identification data) are recorded in the operation data, the above determination may be performed in the order of the value of n from the smallest to the largest.

[0181] The load information determination unit 22 performs the above determination in real time while the actual processing unit 12 is operating, based on the virtual load information obtained in advance by the simulation unit 14 and the actual load information obtained in real time by the actual processing unit 12 .

[0182] The load information determination unit 22 may extract and compare only the virtual load information and the actual load information of a certain specific section in the comparison location identification data.

[0183] When there is no difference between the actual load information and the virtual load information, the numerical controller 110 (operation control unit 24 ) does not perform operation restriction.

[0184] Generally speaking, the acquisition cycle of the position of the movable part in the actual processing part is shorter than the simulation cycle, so the error of the mechanical coordinate Xr(j) where the contact signal is detected in the actual processing part 12 can be ignored. However, when the error of the simulation part 14 is smaller than the error of the actual processing part, the load information determination part 22 may determine that there is no difference between the actual load information and the virtual load information when there is a mechanical coordinate Xs(i) where the contact occurs in the simulation part 14 between the mechanical coordinates Xr(j-1) to Xr(j) in the actual processing part 12. That is, it can be confirmed that the following equation is true for all axes p that move between i-1 and i.

[0185] |Xrp(j)-Xsp(i)|≤|Xrp(j)-Xrp(j-1)|

[0186] (When there is a difference between the actual processing part and the simulation part) (Example where contact is detected only in the simulation part)

[0187] <3-1>

[0188] like Figure 6B As shown, for example, the simulation unit 14 creates time series data Xs(0), Xs(1) to Xs(n) of the machine coordinates Xs(i) of the virtual movable parts 134s and 136s from the start time Ts(0) to the time Ts(i) seconds later as operation data for the simulation unit 14. On the other hand, for example, the numerical control device 110 creates time series data Xr(0), Xr(1) to Xr(n) of the machine coordinates Xr(j) of the movable parts 134 and 136 from the start time Tr(0) to the time Tr(j) seconds later as operation data for the actual processing unit 12 as described above.

[0189] <3-2>

[0190] As described above, the simulation unit 14 performs a machining simulation of the virtual workpiece Ws, and the numerical control device 110 (virtual load acquisition unit 18) acquires the following information: Figure 6B As shown in the figure, ", Ln X_Y_Z_" (virtual load information and comparison location determination data) is added to the operation data.

[0191] <3-3>

[0192] As described above, the drive unit 120 and the actual processing unit 12 process the workpiece W, and the drive unit 120 (actual load acquisition unit 16) acquires the contact signal (actual load information) in a manner associated with the machine coordinates Xr(j) (comparison position identification data). Figure 6B In the example, if the tool T is not in contact with the workpiece W due to damage or installation error of the tool, the drive unit 120 (actual load acquisition unit 16 ) does not acquire a contact signal and thus does not output a contact signal to the numerical controller 110 .

[0193] <3-4>

[0194] Similarly to the above, the numerical control device 110 (load information determination unit 22) compares the contact signal (actual load information) with the presence or absence of contact (virtual load information) based on the machine coordinates Xr(j) and Xs(i) (comparison position determination data) to determine whether there is a difference between these information. Figure 6BIn the process, although the block (comparison part determination data) corresponding to the block recording ", Ln X_Y_Z_" (virtual load information and comparison part determination data) in the operation data of the simulation part 14 has passed through the actual processing part 12, the drive part 120 (actual load acquisition part 16) has not obtained the contact signal, so the numerical control device 110 (load information determination part 22) determines that there is a difference in these information.

[0195] When there is a difference between the actual load information and the virtual load information, the numerical controller 110 (motion control unit 24) decelerates and stops the machine tool 130. The numerical controller 110 (motion control unit 24) can stop the output of the motor immediately or perform a predetermined emergency stop operation. That is, the numerical controller 110 (motion control unit 24) performs output limitation for operating the movable parts 134 and 136, a predetermined retreat operation of the movable parts 134 and 136, or an immediate deceleration and stop of the operation of the movable parts 134 and 136 in the actual machining unit 12.

[0196] In addition, the display unit 28 may also display the mechanical coordinates Xs(i) of the operation data in which the contact (interference) between the virtual tool Ts and the virtual workpiece Ws is detected in the simulation unit 14 in a different color from other operation data, or display it in a flashing manner. Thus, the operator of the machine tool can easily identify the mechanical coordinates Xs(i) of the operation data in which the contact (interference) between the virtual tool Ts and the virtual workpiece Ws is detected in the simulation unit 14.

[0197] (When there is a difference between the actual processing part and the simulated part) (Example where contact is detected only in the actual processing part)

[0198] <3-1>

[0199] like Figure 6C As shown, for example, the simulation unit 14 creates time series data Xs(0), Xs(1) to Xs(n) of the machine coordinates Xs(i) of the virtual movable parts 134s and 136s from the start time Ts(0) to the time Ts(i) seconds later as operation data for the simulation unit 14. On the other hand, for example, the numerical control device 110 creates time series data Xr(0), Xr(1) to Xr(n) of the machine coordinates Xr(j) of the movable parts 134 and 136 from the start time Tr(0) to the time Tr(j) seconds later as operation data for the actual processing unit 12 as described above.

[0200] <3-2>

[0201] As described above, the simulation unit 14 performs a machining simulation of the virtual workpiece Ws, and the numerical control device 110 (virtual load acquisition unit 18) acquires the following information: Figure 6CAs shown in FIG. 1, "Ln X_Y_Z_" (virtual load information and comparison location determination data) is added to the operation data. For example, Figure 6C In the example, since the virtual tool Ts does not enter the virtual workpiece Ws from the outside, there is no record of ", Ln X_Y_Z_" (virtual load information and comparison part determination data) in the operation data. Therefore, the numerical control device 110 (virtual load acquisition unit 18) does not obtain the ", Ln X_Y_Z_" (virtual load information and comparison part determination data) added to the operation data.

[0202] <3-3>

[0203] As described above, the drive unit 120 and the actual machining unit 12 perform machining of the workpiece W, and the drive unit 120 (actual load acquisition unit 16 ) acquires the contact signal (actual load information) in association with the machine coordinates Xr(j) (comparison location identification data).

[0204] <3-4>

[0205] Similarly to the above, the numerical control device 110 (load information determination unit 22) compares the contact signal (actual load information) with the presence or absence of contact (virtual load information) based on the machine coordinates Xr(j) and Xs(i) (comparison position determination data) to determine whether there is a difference between these information. Figure 6C In the block of the operation data of the simulation unit 14 corresponding to the mechanical coordinates Xr(j) (comparison position determination data) where the contact signal (actual load information) is detected in the actual processing unit 12, “, Ln X_Y_Z_” (virtual load information and comparison position determination data) is not recorded, and therefore the numerical control device 110 (load information determination unit 22) determines that there is a difference between these information.

[0206] As described above, when there is a difference between the actual load information and the virtual load information, the numerical controller 110 (motion control unit 24 ) decelerates and stops the machine tool 130 .

[0207] In addition, similarly to the above, the display unit 28 may also display the machine coordinate Xr(j) at which the contact (interference) between the tool T and the workpiece W is detected in the actual processing unit 12 in a color different from other operation data, or display it in a blinking manner. Thus, the operator of the machine tool can easily identify the machine coordinate Xr(j) at which the contact (interference) between the tool T and the workpiece W is detected in the actual processing unit 12.

[0208] [Example 4]

[0209] In Example 4, the magnitude of the load (energy) generated on the movable part when processing the workpiece is used as the actual load information, and the magnitude of the load (energy) generated on the virtual movable part when processing the virtual workpiece is used as the virtual load information. By obtaining the magnitude of the load (energy) instead of obtaining the presence or absence of contact, it is possible to more accurately determine the contact between the tool and the workpiece in the case of gradual cutting, for example.

[0210] <4-1>

[0211] like Figure 7 As shown, for example, the numerical control device 110 analyzes the machining program, creates time series data Xs(0), Xs(1) to Xs(n) of the mechanical coordinates Xs(i) of the virtual movable parts 134s and 136s from the start time Ts(0) to the time Ts(i) seconds later as operation data for the simulation unit 14, and outputs it to the simulation unit 14. In addition, for example, the numerical control device 110 analyzes the machining program, creates time series data Xr(0), Xr(1) to Xr(n) of the mechanical coordinates Xr(j) of the movable parts 134 and 136 from the start time Tr(0) to the time Tr(j) seconds later as operation data for the actual machining unit 12, and outputs it to the drive unit 120. Here, i and j are arbitrary integers from 1 to n. n is an integer greater than 1.

[0212] In addition, in this embodiment, the numerical control device 110 analyzes the machining program and generates the time series data (operation data) of the machine coordinates. However, this embodiment is not limited to this, and the computer constituting the simulation unit 14 or other computers may analyze the machining program and generate the time series data (operation data) of the machine coordinates.

[0213] <4-2>

[0214] The simulation unit 14 performs machining simulation of the virtual workpiece Ws by relatively moving the virtual tool Ts and the virtual workpiece Ws based on the machine coordinates Xs(0) to Xs(n) (operation data) output from the numerical control device 110 .

[0215] The simulation unit 14 calculates the total amount of virtual load Ws(i) [J / s] (energy Ws×t) as virtual load information generated on the virtual movable parts 134s and 136s at a certain machine coordinate Xs(i) at a certain time Ts(i).

[0216] Next, an example of calculation of the total amount of virtual load Ws(i) [J / s] (energy Ws×t) is shown.

[0217] Consider the case where the virtual movable parts 134s and 136s move from the machine coordinates Xs(i-1) at time Ts(i-1) to the machine coordinates Xs(i) at time Ts(i). The energy for removing the virtual workpiece Ws is proportional to the volume to be removed (proportional constant k), and when it is assumed that the total amount of the friction coefficient when the movable part with a mass of m is moved is always fixed (n), the total amount of virtual load Ws(i) per unit time from time T(i-1) to T(i) is expressed by the following formula.

[0218] [Number 1]

[0219]

[0220] In the numerator on the right side of the above formula, the first term is the energy used to remove the virtual workpiece Ws, the second term is the change in kinetic energy, the third term is the change in potential energy, and the fourth term is the energy consumed by the movement of the virtual movable part.

[0221] Vs(i) is the volume of the removal area, which is the area where the virtual tool Ts passes through and the area of ​​the virtual workpiece Ws overlap between Ts(i-1) and Ts(i). Vs(i) is the speed of i, which is expressed by the following formula.

[0222] [Number 2]

[0223]

[0224] In addition, the simulation unit 14 calculates a certain machine coordinate Xs(i) at a certain time Ts(i) as comparison location determination data for determining a comparison location between the virtual load information and the actual load information. Specifically, the comparison location determination data is data that corresponds the time series or processing position of the virtual load information and the actual load information. More specifically, the comparison location determination data is data that makes a one-to-one correspondence between the time Ts(i) when the virtual tool Ts contacts the virtual workpiece Ws in the simulation unit 14 and the time Tr(j) when the tool T contacts the workpiece W in the actual processing unit 12. That is, the comparison location determination data is data that determines the time Ts(i) and the time Tr(j) as the comparison location between the virtual load information and the actual load information. Thus, the load information determination unit 22 can appropriately compare the virtual load information at the time Ts(i) and the actual load information at the time Tr(j) based on the comparison location determination data.

[0225] Furthermore, as described above, the simulation unit 14 may be provided in the numerical control device 110 , or may be constituted by a computer different from the numerical control device 110 .

[0226] The numerical control device 110 (virtual load acquisition unit 18) is as follows Figure 7As shown, the load Ws(i) [J / s] (energy Ws×t) (virtual load information) is acquired in a manner associated with the time Ts(i) (comparison site identification data).

[0227] The simulation unit 14 performs the above-mentioned machining simulation before the actual machining unit 12 operates based on the operation data to pre-calculate the virtual load information and the comparison location determination data. In addition, the virtual load acquisition unit 18 may acquire the virtual load information in advance in a manner associated with the comparison location determination data and temporarily store it in the storage unit 20 before the actual machining unit 12 operates based on the operation data.

[0228] <4-3>

[0229] The driving unit 120 drives the motor 132 and movable parts 134 and 136 of the actual processing unit 12 based on the machine coordinates Xr(0) to Xr(n) (operation data) output from the numerical controller 110. Thus, the actual processing unit 12 processes the workpiece W by moving the tool T and the workpiece W relative to each other.

[0230] The drive unit 120 (actual load acquisition unit 16) calculates the total amount of the motor load Wr(j)[J / s](energy Wr×t) as the actual load information generated on the movable parts 134 and 136 at a certain machine coordinate Xr(j) at a certain time Tr(j). The calculation of the load Wr(j)[J / s](energy Wr×t) may be the same as the example of the calculation of the load Ws(i)[J / s](energy Ws×t) described above.

[0231] When the machine tool is an electrical discharge machine, the total amount of the load on the motor may be added with the power flowing through the tool.

[0232] The driving unit 120 (actual load acquisition unit 16) is as follows Figure 7 As shown, the load Wr(j) [J / s] (energy Wr×t) (actual load information) is acquired in a manner associated with the time Tr(j) (comparison site identification data).

[0233] <4-4>

[0234] The numerical control device 110 (load information determination unit 22) compares the load Wr(j) [J / s] (energy Wr×t) (actual load information) with the load Ws(i) [J / s] (energy Ws×t) (virtual load information) based on the time Tr(j) and Ts(i) (comparison location determination data) to determine whether there is a difference between these information. Figure 7 In the example, the numerical control device 110 (load information determination unit 22) obtains the minimum j (jmin) and the maximum j (jmax) that satisfy the following equation at the time Ts(i).

[0235] Ts(i-1)≤Tr(j)≤Ts(i)

[0236] The numerical control device 110 (load information determination unit 22) determines whether the following equation is satisfied at time i. If the following equation is satisfied, the numerical control device 110 (load information determination unit 22) determines that there is no difference between the actual load information and the virtual load information.

[0237] [Number 3]

[0238]

[0239] Here, jmin and jmax are the minimum j and maximum j that satisfy Ts(i-1)≤Tr(j)<Ts(i), ΔTs is the simulation period, ΔTr is the period for obtaining the motor output in the actual machining part, and ΔW[J] is a certain threshold value representing the load of the motor. In addition, the above formula is based on the premise that ΔTs>ΔTr.

[0240] Furthermore, when the motor output is smaller than a certain threshold value, it is considered that the workpiece and the tool are not in contact in the actual processing portion, and no comparison may be performed.

[0241] The load information determination unit 22 performs the above determination in real time while the actual processing unit 12 is operating, based on the virtual load information obtained in advance by the simulation unit 14 and the actual load information obtained in real time by the actual processing unit 12 .

[0242] The load information determination unit 22 may extract and compare only the virtual load information and the actual load information of a specific section in the comparison location identification data.

[0243] When there is no difference between the actual load information and the virtual load information, the numerical controller 110 (operation control unit 24 ) does not perform operation restriction.

[0244] As described above, the load information determination unit 22 may be provided in the numerical controller 110 or the drive unit 120 (servo control unit, amplifier), or may be composed of a computer different from the numerical controller 110 and the drive unit 120 .

[0245] [Example 5]

[0246] In the above-mentioned embodiments 1 to 4, the method of limiting the motion of the actual machining is illustrated by assuming that there is a problem with the actual machining. In the fifth embodiment, when there is a problem with the setting of the machining simulation, the setting of the machining simulation is changed (corrected). In this way, by reflecting the difference between the actual load information and the virtual load information in the machining simulation, the simulation accuracy can be improved.

[0247] <5-1>

[0248] like Figure 8 As shown, for example, the numerical control device 110 analyzes the machining program, creates time series data Xs(0), Xs(1) to Xs(n) of the mechanical coordinates Xs(i) of the virtual movable parts 134s and 136s from the start time Ts(0) to the time Ts(i) seconds later as operation data for the simulation unit 14, and outputs it to the simulation unit 14. In addition, for example, the numerical control device 110 analyzes the machining program, creates time series data Xr(0), Xr(1) to Xr(n) of the mechanical coordinates Xr(j) of the movable parts 134 and 136 from the start time Tr(0) to the time Tr(j) seconds later as operation data for the actual machining unit 12, and outputs it to the drive unit 120. Here, i and j are arbitrary integers from 1 to n. n is an integer greater than 1.

[0249] In addition, in this embodiment, the numerical control device 110 analyzes the machining program and generates the time series data (operation data) of the machine coordinates. However, this embodiment is not limited to this, and the computer or other computer constituting the simulation unit 14 may analyze the machining program and generate the time series data (operation data) of the machine coordinates.

[0250] <5-2>

[0251] The driving unit 120 drives the motor 132 and movable parts 134 and 136 of the actual processing unit 12 based on the machine coordinates Xr(0) to Xr(n) (operation data) output from the numerical controller 110. Thus, the actual processing unit 12 processes the workpiece W by moving the tool T and the workpiece W relative to each other.

[0252] The drive unit 120 (actual load acquisition unit 16) acquires contact information indicating whether the tool T is in contact with the workpiece W as load information generated on the movable parts 134 and 136 at a certain mechanical coordinate Xr(j) at a certain time Tr(j). For example, the drive unit 120 (actual load acquisition unit 16) monitors the output (command or feedback information) of the motor 132, and sets the contact signal to 0 when the output of the motor 132 does not exceed a certain threshold value, and determines that the tool T is in contact with the workpiece W when the output of the motor 132 exceeds a certain threshold value, and sets the contact signal to 1.

[0253] The driving unit 120 (actual load acquisition unit 16 ) acquires the contact signal (actual load information) in a manner associated with the machine coordinates Xr(j) (comparison site identification data).

[0254] The comparison location determination data is data that associates the virtual load information with the time series or processing position of the actual load information. More specifically, the comparison location determination data is data that associates the machine coordinate Xs(i) where the virtual tool Ts contacts the virtual workpiece Ws in the simulation unit 14 with the machine coordinate Xr(j) where the tool T contacts the workpiece W in the actual processing unit 12. That is, the comparison location determination data is data that identifies the machine coordinate Xs(i) and the machine coordinate Xr(j) as the comparison location of the virtual load information and the actual load information. Thus, the load information determination unit 22 can appropriately compare the virtual load information of the machine coordinate Xs(i) and the actual load information of the machine coordinate Xr(j) based on the comparison location determination data.

[0255] <5-3>

[0256] The simulation unit 14 performs machining simulation of the virtual workpiece Ws by relatively moving the virtual tool Ts and the virtual workpiece Ws based on the machine coordinates Xs(0) to Xs(n) (operation data) output from the numerical control device 110 .

[0257] The simulation unit 14 calculates contact information indicating whether the virtual tool Ts is in contact with the virtual workpiece Ws as virtual load information generated on the virtual movable part 134s, 136s at a certain machine coordinate Xs(i) at a certain time Ts(i). For example, the simulation unit 14 sets the contact flag to 0 when the virtual tool Ts is outside the virtual workpiece Ws, and sets the contact flag to 1 when the virtual tool Ts moves from the outside to the inside of the virtual workpiece Ws.

[0258] Furthermore, the simulation unit 14 calculates a certain machine coordinate Xs(i) at a certain time Ts(i) as comparison location identification data for identifying a comparison location between the virtual load information and the actual load information.

[0259] Furthermore, as described above, the simulation unit 14 may be provided in the numerical control device 110 , or may be constituted by a computer different from the numerical control device 110 .

[0260] The numerical control device 110 (virtual load acquisition unit 18 ) acquires the contact flag 0 / 1 (virtual load information) in a manner associated with the machine coordinate Xs(i) (comparison site identification data).

[0261] <5-4>

[0262] The simulation unit 14 (load information determination unit 22) compares the contact signal (actual load information) with the contact flag (virtual load information) based on the machine coordinates Xr(j) and Xs(i) (comparison position determination data) to determine whether there is a difference between these information. Figure 8In the embodiment, the numerical control device 110 (load information determination unit 22) determines that there is a difference between the actual load information and the virtual load information based on the machine coordinates Xr(j) and Xs(i) (comparison part determination data), when the machine coordinates Xr(j) (comparison part determination data) at which a contact signal (actual load information) is detected in the actual processing unit 12 is different from the machine coordinates Xs(i) (comparison part determination data) at which the contact mark (virtual load information) changes from 0 to 1 in the simulation unit 14.

[0263] The load information determination unit 22 may extract and compare only the virtual load information and the actual load information of a specific section in the comparison location identification data.

[0264] When there is a difference between the actual load information and the virtual load information, the simulation unit 14 (correction unit 26) changes (corrects) the preconditions of the simulation unit 14. The preconditions of the simulation unit 14 include, for example, items recorded in the operation data, including preconditions related to the virtual tool, the virtual workpiece, and the virtual movable part.

[0265] For example, in Figure 8 In the process, the simulation unit 14 (correction unit 26) calculates the difference between the mechanical coordinates in the simulation unit 14 corresponding to the mechanical coordinates Xr(j) of the contact signal (actual load information) detected in the actual processing unit 12 and the mechanical coordinates of the boundary of the virtual workpiece Ws, and reflects the difference in the premise of the simulation unit by changing it to the set value of the radius R of the virtual tool Ts.

[0266] Alternatively, the simulation unit 14 (correction unit 26) may calculate the difference between the mechanical coordinates Xr(j) of the contact signal (actual load information) detected in the actual processing unit 12 and the mechanical coordinates Xs(i) of the contact mark (virtual load information) detected in the simulation unit 14, and reflect the difference as the correction amount of the virtual tool Ts in the premise of the simulation unit to change (correct) the setting value of the virtual tool Ts by the correction amount.

[0267] Alternatively, the simulation unit 14 (correction unit 26) may determine the process in which there is a difference in these information in the operation data based on the mechanical coordinates Xr(j) (comparison position determination data) where the contact signal (actual load information) is detected in the actual processing unit 12 and the mechanical coordinates Xs(i) (comparison position determination data) where the contact mark (virtual load information) changes from 0 to 1 in the simulation unit 14, and change (correct) the prerequisites for the processing simulation.

[0268] As described above, according to the processing load determination system 10 of the present embodiment, the virtual load information of the processing simulation is obtained in a manner associated with the comparison part determination data, and the actual load information of the actual processing is obtained in a manner associated with the comparison part determination data. Therefore, even if the processing simulation is not performed in real time for the actual processing, these load information can be appropriately compared based on the comparison part determination data. Therefore, the processing simulation can be performed in advance before the actual processing, and there is no need to shorten the processing time of the processing simulation according to the action time of the actual processing. The accuracy of the processing simulation is not limited, that is, the accuracy of the processing simulation can be improved. Therefore, the detection accuracy of the difference between the processing simulation and the actual processing can be improved, so that the erroneous action that could not be prevented in the past can be accurately detected.

[0269] Here, in the technology disclosed in Patent Document 1, when repeating the same action with the same operation data, it is necessary to always continue to perform the same simulation, which requires resources. In this regard, in the present embodiment, it is not necessary to perform machining simulation every time actual machining is performed, and resources can be reduced compared to the technology disclosed in Patent Document 1.

[0270] Although the present disclosure is described in detail, the present disclosure is not limited to the above-mentioned embodiments. These embodiments can be variously added, replaced, changed, partially deleted, etc. without departing from the scope of the gist of the present disclosure, or without departing from the scope of the purpose of the present disclosure derived from the contents recorded in the claims and their equivalents. In addition, these embodiments can also be implemented in combination. For example, in the above-mentioned embodiments, the order of each action and the order of each processing are shown as an example and are not limited to this. In addition, the same is true for the case where numerical values ​​or formulas are used in the description of the above-mentioned embodiments.

[0271] The following additional notes are disclosed in relation to the above-mentioned embodiment and modified examples.

[0272] (Note 1)

[0273] A processing load determination system (10) comprising:

[0274] An actual processing section (12) having a movable section (134, 136), on which a tool (T) or a workpiece (W) is arranged, and the actual processing section (12) processes the workpiece (W) by relatively moving the tool (T) and the workpiece (W) based on operation data;

[0275] a simulation unit (14) for performing a machining simulation of the virtual workpiece (Ws) by relatively moving the virtual tool (Ts) and the virtual workpiece (Ws) based on the operation data in a virtual space (VS) including a virtual tool (Ts) corresponding to the tool (T), a virtual workpiece (Ws) corresponding to the workpiece (W), and a virtual movable part (134s, 136s) corresponding to the movable part (134, 136);

[0276] a virtual load acquisition unit (18) for acquiring virtual load information generated on the virtual movable part (134s, 136s) obtained by machining simulation performed by the simulation unit (14);

[0277] an actual load acquisition unit (16) for acquiring information on an actual load generated on the movable part (134, 136) through processing by the actual processing unit (12); and

[0278] A load information determination unit (22) compares the virtual load information with the actual load information to determine whether there is a difference between the information.

[0279] wherein the simulation unit (14) calculates the virtual load information and comparison location determination data, the comparison location determination data being used to determine a comparison location between the virtual load information and the actual load information,

[0280] The virtual load acquisition unit (18) acquires the virtual load information in a manner associated with the comparison location identification data.

[0281] The actual load acquisition unit (16) acquires the actual load information in a manner associated with the comparison location identification data.

[0282] The load information determination unit (22) compares the virtual load information with the actual load information based on the comparison location identification data.

[0283] (Note 2)

[0284] In the above-mentioned machining load determination system (10),

[0285] The comparison location identification data for the actual load information includes at least one of position information and time information of the movable part (134, 136),

[0286] The comparison location identification data used for the virtual load information includes at least any one of position information and time information of the virtual movable part (134s, 136s) and the operation data.

[0287] (Note 3)

[0288] In the above-mentioned machining load determination system (10),

[0289] The actual load information includes energy generated in the movable part (134, 136) when the workpiece (W) is processed.

[0290] The virtual load information includes energy generated in the virtual movable part (134s, 136s) when the virtual workpiece (Ws) is processed.

[0291] (Note 4)

[0292] In the above-mentioned machining load determination system (10),

[0293] The actual load information is contact information indicating whether the tool (T) is in contact with the workpiece (W).

[0294] The virtual load information is contact information indicating whether the virtual tool (Ts) is in contact with the virtual workpiece (Ws).

[0295] (Note 5)

[0296] In the above-mentioned machining load determination system (10),

[0297] The load information determination unit (22) performs the determination in real time while the actual processing unit (12) is operating.

[0298] (Note 6)

[0299] In the above-mentioned machining load determination system (10),

[0300] When the load information determination unit (22) determines that there is a difference between the virtual load information and the actual load information, at least one of the following is performed in the actual processing unit (12) for limiting the output of the movable part (134, 136) to cause the movable part (134, 136) to move, a pre-set retreat action of the movable part (134, 136), and an immediate deceleration and stop of the action of the movable part (134, 136).

[0301] (Note 7)

[0302] In the above-mentioned machining load determination system (10),

[0303] The simulation unit (14) performs the machining simulation based on the operation data including preconditions related to the virtual tool (Ts), the virtual workpiece (Ws), and the virtual movable part (134s, 136s).

[0304] When the load information determination unit (22) determines that there is a difference between the virtual load information and the actual load information, the simulation unit (14) determines the process where the difference between the information exists in the operation data based on the comparison location determination data, and changes the preconditions of the machining simulation.

[0305] (Note 8)

[0306] In the above-mentioned machining load determination system (10),

[0307] The actual load information is contact information indicating whether the tool (T) is in contact with the workpiece (W).

[0308] The virtual load information is contact information indicating whether the virtual tool (Ts) is in contact with the virtual workpiece (Ws).

[0309] The comparison location identification data for the actual load information includes position information of the movable part (134, 136),

[0310] The comparison location identification data for the virtual load information includes position information of the virtual movable part (134s, 136s),

[0311] The simulation unit (14) performs the machining simulation based on the operation data including preconditions related to the virtual tool (Ts), the virtual workpiece (Ws), and the virtual movable part (134s, 136s).

[0312] When the load information determination unit (22) determines that there is a difference between the virtual load information and the actual load information, the simulation unit (14) calculates the difference between the machine coordinates at which the tool (t) in the actual machining unit (12) contacts the workpiece (W) and the machine coordinates at which the virtual tool (Ts) in the simulation unit (14) contacts the virtual workpiece (Ws),

[0313] The simulation unit (14) changes the precondition of the virtual tool (Ts) by using the difference as a correction amount of the virtual tool (Ts).

[0314] (Note 9)

[0315] In the above-mentioned machining load determination system (10),

[0316] The simulation unit (14) performs the machining simulation before the actual machining unit (12) operates based on the operation data, and calculates the comparison location identification data and the virtual load information in advance.

[0317] (Note 10)

[0318] In the above-mentioned machining load determination system (10),

[0319] The virtual load acquisition unit (18) records at least one of the comparison location identification data and the virtual load information in the operation data.

[0320] (Note 11)

[0321] In the above-mentioned machining load determination system (10),

[0322] A display unit (28) is provided for displaying the comparison location identification data for which the load information determination unit (22) determines that the virtual load information and the actual load information differ in a different display mode according to the difference.

[0323] (Note 12)

[0324] In the above-mentioned machining load determination system (10),

[0325] The load information determination unit (22) extracts and compares the virtual load information and the actual load information only in a specific section of the comparison location identification data.

[0326] Description of Reference Numerals

[0327] 10: machining load determination system; 12: actual machining unit; 14: simulation unit; 16: actual load acquisition unit; 18: virtual load acquisition unit; 20: storage unit; 22: load information determination unit; 24: motion control unit; 26: calibration unit; 28: display unit; 100: industrial machinery system; 110: numerical control device; 120: drive unit; 130: machine tool (industrial machinery); 132: motor; 134: mounting unit (movable unit); 134s: virtual mounting unit (virtual movable unit); 136: workbench (movable unit); 136s: virtual workbench (virtual movable unit); T: tool; Ts: virtual tool; VS: virtual space; W: workpiece (machining object); Ws: virtual workpiece (virtual machining part).

Claims

1. A processing load determination system comprising: an actual processing section having a movable section on which a tool or a workpiece is provided, and the actual processing section processes the workpiece by relatively moving the tool and the workpiece based on operation data; a simulation unit for performing machining simulation of the virtual workpiece by relatively moving the virtual tool and the virtual workpiece based on the operation data in a virtual space including a virtual tool corresponding to the tool, a virtual workpiece corresponding to the workpiece, and a virtual movable part corresponding to the movable part; a virtual load acquisition unit that acquires virtual load information generated on the virtual movable part obtained by the machining simulation performed by the simulation unit; an actual load acquisition unit that acquires information on an actual load generated on the movable portion through processing by the actual processing unit; as well as a load information determination unit, which compares the virtual load information with the actual load information to determine whether there is a difference between the information, wherein the simulation unit calculates the virtual load information and comparison location determination data, the comparison location determination data being used to determine a comparison location between the virtual load information and the actual load information, The virtual load acquisition unit acquires the virtual load information in a manner associated with the comparison location identification data. The actual load acquisition unit acquires the actual load information in a manner associated with the comparison site identification data. The load information determination unit compares the virtual load information with the actual load information based on the comparison location identification data.

2. The processing load determination system according to claim 1, wherein: The comparison location identification data for the actual load information includes at least one of position information and time information of the movable part. The comparison portion identification data used for the virtual load information includes at least any one of position information and time information of the virtual movable part and the operation data.

3. The processing load determination system according to claim 1 or 2, wherein: The actual load information includes energy generated in the movable part when the workpiece is processed. The virtual load information includes energy generated in the virtual movable part when the virtual workpiece is processed.

4. The processing load determination system according to claim 1 or 2, wherein: The actual load information is contact information indicating whether the tool is in contact with the workpiece. The virtual load information is contact information indicating whether the virtual tool is in contact with the virtual workpiece.

5. The machining load determination system according to any one of claims 1 to 4, wherein: The load information determination unit performs the determination in real time while the actual machining unit is operating.

6. The machining load determination system according to any one of claims 1 to 5, wherein: When the load information determination unit determines that there is a difference between the virtual load information and the actual load information, at least one of output limitation for moving the movable part, a pre-set retreat action of the movable part, and immediate deceleration and stop of the action of the movable part is performed in the actual processing unit.

7. The machining load determination system according to any one of claims 1 to 4, wherein: The simulation unit performs the machining simulation based on the operation data including preconditions related to the virtual tool, the virtual workpiece, and the virtual movable unit. When the load information determination unit determines that there is a difference between the virtual load information and the actual load information, the simulation unit specifies a process in the operation data where there is a difference in these information based on the comparison location identification data, and changes a precondition of the machining simulation.

8. The machining load determination system according to any one of claims 1 to 4, wherein: The actual load information is contact information indicating whether the tool is in contact with the workpiece. The virtual load information is contact information indicating whether the virtual tool is in contact with the virtual workpiece. The comparison location identification data for the actual load information includes position information of the movable part. The comparison location identification data used for the virtual load information includes position information of the virtual movable part. The simulation unit performs the machining simulation based on the operation data including preconditions related to the virtual tool, the virtual workpiece, and the virtual movable unit. When the load information determination unit determines that there is a difference between the virtual load information and the actual load information, the simulation unit calculates the difference between the mechanical coordinates at which the tool in the actual machining unit contacts the workpiece and the mechanical coordinates at which the virtual tool in the simulation unit contacts the virtual workpiece, The simulation unit changes the precondition of the virtual tool by using the difference as a correction amount of the virtual tool.

9. The machining load determination system according to any one of claims 1 to 5, wherein: The simulation unit performs the machining simulation before the actual machining unit operates based on the operation data, and calculates the comparison portion identification data and the virtual load information in advance.

10. The processing load determination system according to claim 2, wherein: The virtual load acquisition unit records at least one of the comparison location identification data and the virtual load information in the operation data.

11. The machining load determination system according to any one of claims 1 to 10, wherein: A display unit is provided for displaying the comparison location identification data determined by the load information determination unit as having a difference between the virtual load information and the actual load information in a different display mode according to the difference.

12. The machining load determination system according to any one of claims 1 to 10, wherein: The load information determination unit extracts and compares only the virtual load information and the actual load information of a specific section in the comparison location identification data.

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