processing system

Abstract

Machining system (10, 10A, 10B) comprising a machine tool (12) and a 3D shape generating device (14, 14A, 14B) configured to generate a three-dimensional shape of a part of the machine tool (12), wherein the machine tool (12) comprises: a spindle (20) to which a tool (22) is attached; a table (28) adapted to support a workpiece; a motor configured to drive a movement mechanism configured to move the spindle (20) and the table (28); and a camera (50, 50A) designed to move together with the table (28) with respect to the spindle (20) to take an image of the side of the spindle (20), or to move together with the spindle (20) with respect to the table (28) to take an image of the side of the table (28), the 3D shape generating device (14, 14A, 14B) comprises: an image capture unit (60) configured to capture a first image from the camera (50, 50A) when a relative position of the table (28) with respect to the spindle (20) is at a first relative position, and to capture a second image from the camera (50, 50A) when the relative position is at a second relative position different from the first relative position; and a shape generator (62, 62A) configured to generate a three-dimensional shape of at least one subject based on the first image, the second image and a first relative distance (D) between the first relative position and the second relative position.

Description

BACKGROUND OF THE INVENTIONField of the invention:

[0001] The present invention relates to a processing system. Description of the state of the art:

[0002] JP 2016-91142 A discloses a machining system comprising a machine tool, peripheral devices, and a numerical control device for operating the machine tool in conjunction with the peripheral devices. The numerical control device of this machining system outputs arrangement data of elements in the machine tool based on the machining program and shape data of elements used in the machine tool, such as tools, workpieces, fixtures, etc. Based on the element arrangement data, the peripheral devices are configured to start operation at a time such that the movement of the peripheral devices does not interfere with the driven elements in the machine tool.

[0003] From DE 10 2015 119 806 A1 a method for displaying the machining processes in the machining area of ​​a machine tool is known, whereby a tool or workpiece is scanned and the machining process is visualized. SUMMARY OF THE INVENTION

[0004] In the case of JP 2016 - 91 142 A, since the shape data of elements such as tools etc. are stored in advance in the memory, it can be assumed that the shape of the respective tool differs from the shape data stored in the memory, for example due to tool wear caused by the machining of workpieces.

[0005] Therefore, an object of the present invention is to provide a machining system that can easily and accurately produce a three-dimensional shape.

[0006] This problem is solved by a processing system having the features of patent claim 1.

[0007] One aspect of the present invention is a machining system comprising a machine tool and a 3D shape generating device configured to generate a three-dimensional shape of a part of the machine tool. The machine tool includes: a spindle to which a tool is mounted; a table configured to support a workpiece; a motor configured to drive a moving mechanism configured to move the spindle and the table; and a camera configured to move together with the table with respect to the spindle to capture an image of the side of the spindle, or to move together with the spindle with respect to the table to capture an image of the side of the table.The 3D shape generating device comprises: an image capturing unit configured to capture a first image from the camera when a relative position of the table with respect to the spindle is at a first relative position, and to capture a second image from the camera when the relative position is at a second relative position different from the first relative position; and a shape generator configured to generate a three-dimensional shape of at least one subject based on the first image, the second image, and a first relative distance between the first relative position and the second relative position.

[0008] According to the present invention, since a camera that moves along with the stage relative to the spindle or a camera that moves along with the spindle relative to the stage is used, a three-dimensional shape of a subject can be generated more accurately than when a camera that does not move relatively is used. In addition, a three-dimensional shape can be generated more easily than when two cameras are used to generate a three-dimensional shape.

[0009] The foregoing and other objects, features and advantages of the present invention will become more apparent from the following description taken in conjunction with the accompanying drawings in which a preferred embodiment of the present invention is shown by way of illustrative example. BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 is a schematic diagram showing a machining system of the embodiment. Fig. 2 is a block diagram showing a configuration of a 3D shape generating apparatus according to the embodiment. Fig. 3 shows a conceptual diagram illustrating a state of image acquisition. Fig. Figure 4 shows a conceptual diagram showing a result of comparison between three-dimensional shapes. Fig. 5 is a flowchart showing a control sequence of 3D shape generation of a machining system of the embodiment. Fig. 6 is a flowchart showing a control sequence of a pre-machining shape generation process. Fig. Figure 7 shows a flowchart illustrating a control sequence of an estimation process. Fig. Figure 8 shows a schematic diagram illustrating a machining system of modification 1. Fig. 9 is a block diagram showing a configuration of a 3D shape generating apparatus according to Modification 1. Fig. 10 shows a conceptual diagram showing a result of comparison between three-dimensional shapes. Fig. 11 is a view showing a state in which a camera lens is colored with working fluid. Fig. 12 shows a diagram illustrating a machining system of modification 7. DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0010] Hereinafter, a machining system according to the present invention will be explained by describing preferred embodiments with reference to the accompanying drawings.

[0011] Fig. 1 shows a schematic diagram illustrating a machining system 10. The machining system 10 includes a machine tool 12 and a 3D shape generating device 14. The machine tool 12 has a machine tool body 16 and a control device 18 for controlling the machine tool body 16. The control device 18 and the 3D shape generating device 14 communicate with each other wirelessly or by wire to exchange various types of information.

[0012] The machine tool body 16 machines a workpiece (an object to be machined) not shown with a tool 22 attached to a spindle 20. The machine tool body 16 includes a spindle 20, a spindle head 24 supporting the spindle 20, a column 26 for moving the spindle head 24 in the Z direction and the negative Z direction (in the vertical direction), a table 28 arranged below the spindle 20 (negative Z direction) and configured to support the workpiece, and a table drive unit 30 for moving the table 28 in the X direction and the Y direction. Ideally, the X direction, the Y direction, and the Z direction are assumed to be orthogonal to each other. The direction of gravity acts in the negative Z direction.

[0013] The tool 22 is attached to the spindle 20 with a tool holder 32 detachably attached to the spindle 20. The tool holder 32 may include a vibration damping mechanism, such as a hydraulic clamping device. The tool 22, attached to the spindle 20 with the tool holder 32, has its longitudinal direction along the spindle 20, and the spindle 20 and the tool 22 rotate together. Examples of the tool 22 include non-rotating tools (spring collar tools), drills, end mills, milling cutters, and the like.

[0014] The machine tool body 16 is designed as a machining center that can change the tool 22 mounted on the spindle 20 using an automatic tool changer 34. The tool changer 34 has a tool magazine 36 that can accommodate (hold) a plurality of tools 22, each of which is held by a tool holder 32.

[0015] The spindle head 24 is equipped with at least one unillustrated Z-axis moving mechanism for moving the spindle head 24 with respect to the column 26 in the Z-axis direction parallel to the Z direction, and a Z-axis motor for driving the Z-axis moving mechanism. The Z-axis moving mechanism includes a power conversion mechanism (ball screw, nut, etc.) that converts the rotational motion of the Z-axis motor into linear motion and transmits the motion to the spindle head 24. As the spindle head 24 moves in the Z direction, the spindle 20 supported by the spindle head 24 also moves in the Z direction, and the tool 22 attached to the spindle 20 also moves in the Z direction.

[0016] The spindle head 24 is equipped with a coolant nozzle 37 for spraying a cutting fluid onto the tool 22 during machining. The spindle motor 24 has an internal spindle motor (not shown) that causes the spindle 20 to rotate about the Z-axis parallel to the Z-direction. As the spindle 20 rotates about the Z-axis, the tool 22 attached to the spindle 20 also rotates about the Z-axis.

[0017] The table 28 has a plurality of locking grooves 38 formed in one surface thereof, extending linearly in the X direction and arranged at predetermined intervals along the Y direction. The workpiece is fixed to the table 28 by a fastening jig (not shown). The fastening jig is designed to secure the object to be machined to the surface of the table 28 with the locking grooves 38.

[0018] The table drive unit 30 moves the table 28 in the X-direction and Y-direction and is supported by a base 40. The table drive unit 30 includes Y-axis sliders 42, a carriage 44, and X-axis sliders 46. The carriage 44 is supported to be movable in the Y-direction with respect to the base 40 by the Y-axis sliders 42. The table 28 is supported to be movable in the X-direction with respect to the carriage 44 by the X-axis sliders 46.

[0019] The carriage 44 is equipped with at least one Y-axis movement mechanism (not shown) for moving the carriage 44 in the Y-axis direction parallel to the Y direction with respect to the base 40, and a Y-axis motor for driving the Y-axis movement mechanism. The Y-axis movement mechanism includes a force conversion mechanism (ball screw, nut, etc.) for converting the rotational movement of the Y-axis motor into a linear movement and transmitting the movement to the carriage 44.

[0020] Likewise, the table 28 is equipped with at least one X-axis movement mechanism (not shown) for moving the table 28 in the X-axis direction parallel to the X-direction with respect to the carriage 44, and an X-axis motor for driving the X-axis movement mechanism. The X-axis movement mechanism includes a force conversion mechanism (ball screw, nut, etc.) for converting the rotary motion of the X-axis motor into linear motion and transmitting the motion to the table 28.

[0021] The machine tool body 16 includes a camera 50. The camera 50 is for capturing an image of the spindle 20 side and is arranged to move relatively together with the table 28 with respect to the spindle 20. In the present embodiment, the camera 50 is arranged on the surface of the table 28 and captures images of the tool 22, the tool holder 32, the spindle 20, the coolant nozzle 37, and the spindle head 24 as the subjects.

[0022] The control device 18 includes at least a processor, a memory, and an input unit, such as a keyboard. Upon receiving a machining command for machining the workpiece from the input unit, the control device 18 sequentially executes the pre-machining mode, machining mode, and post-machining mode based on the program stored in the memory.

[0023] That is, in the pre-processing mode, the controller 18 individually controls the X-axis motor, the Y-axis motor, and the Z-axis motor to move the spindle 20 and the table 28 relative to each other from a predetermined start position to a predetermined end position. Furthermore, the controller 18 outputs position information indicating the position (relative position) of the table 28 with respect to the spindle 20 according to the previous relative movement to the 3D shape generating device 14.

[0024] Upon completion of the relative movement to the predetermined end position, the control device 18 is ready to receive a signal indicating the success or failure of the generation of the preliminary 3D shape from the 3D shape generation device 14. Upon receiving a failure signal from the 3D shape generation device 14, the control device 18 moves the spindle 20 and the table 28 relative to each other again from the predetermined start position to the predetermined end position and outputs the position information to the 3D shape generation device 14.

[0025] Upon receiving a success signal from the 3D shape generating device 14, the control device 18 starts the machining mode. In the machining mode, the control device 18 individually controls the X-axis motor, the Y-axis motor, and the Z-axis motor and moves the spindle 20 and the table 28 relative to each other to machine the workpiece supported on the table 28 into a specified shape using the tool 22 attached to the spindle 20.

[0026] Upon completion of the workpiece machining, the controller 18 switches to the post-processing mode. In the post-processing mode, the controller 18 individually controls the X-axis motor, the Y-axis motor, and the Z-axis motor to move the spindle 20 and the table 28 relative to each other from the same starting position as in the pre-processing mode to the final position. Furthermore, the controller 18 outputs the position information corresponding to this relative movement to the 3D shape generation device 14.

[0027] Upon completion of the relative movement to the predetermined end position, the control device 18 is ready to receive a signal indicating the success or failure of the generation of the post-processing 3D shape from the 3D shape generation device 14. Upon receiving a failure signal from the 3D shape generation device 14, the control device 18 moves the spindle 20 and the table 28 relative to each other again from the predetermined start position to the predetermined end position and outputs the position information to the 3D shape generation device 14.

[0028] Upon receiving a success signal from the 3D shape generating device 14, the control device 18 moves the spindle 20 and the table 28 relative to each other and returns the spindle 20 and the table 28 to their original positions. Upon receiving an abnormality signal from the 3D shape generating device 14 before the completion of the post-processing mode, the control device 18 terminates the mode currently being executed when the abnormality signal is received, and the spindle 20 and the table 28 are returned to their original positions.

[0029] The 3D shape generation device 14 has a 3D shape generation mode and an estimation mode. In the 3D shape generation mode, the 3D shape generation device 14 generates a three-dimensional shape (hereinafter referred to as a "pre-processing shape") based on the image generated by the control device 18 before processing the workpiece and the imaging result of the camera 50, and stores the generated pre-processing shape.

[0030] Further, in the 3D shape generation mode, the 3D shape generation device 14 generates a three-dimensional shape (hereinafter referred to as "post-processing shape") based on the image obtained by the control device 18 after processing the workpiece and the imaging result of the camera 50, and stores the generated post-processing shape.

[0031] In the estimation mode, the 3D shape generating device 14 protects the state of the subjects captured by the camera 50 based on the pre-processing shape and the post-processing shape and reports the estimated state to an operator.

[0032] Fig. 2 is a block diagram showing a configuration of the 3D shape generating device 14. The 3D shape generating device 14 includes an image acquisition unit 60, a shape generator 62, a storage unit 64, a shape comparator 66, a state estimator 68, and a notifier 70.

[0033] In the 3D shape generating device 14, the image acquisition unit 60 and the shape generator 62 operate in the 3D shape generating mode, while the shape comparator 66, the state estimator 68, and the notifier 70 operate in the estimation mode.

[0034] The image capture unit 60 captures an image from the camera 50 based on the position information provided by the control device 18 before or after processing. Fig. Figure 3 shows a conceptual diagram illustrating a state of image acquisition. For simplicity, Fig. 3 a case where the table 28 is moved relatively along the XY plane (horizontally) with respect to the spindle 20.

[0035] Upon receiving the position information from the control device 18, the image acquisition unit 60 acquires a first image from the camera 50 based on the position information when the position (relative position) of the table 28 with respect to the spindle 20 is at a first relative position (see the dashed line in Fig. 3).

[0036] Further, when the position (relative position) of the table 28 with respect to the spindle 20 is at a second relative position different from the first relative position, the image acquisition unit 60 acquires a second image from the camera 50 based on the position information (see solid line in Fig. 3). Upon acquiring the first image and the second image, the image acquisition unit 60 outputs the acquired first and second images and the first and second relative positions to the shape generator 62. The first relative position and the second relative position are determined before and after processing.

[0037] The shape generator 62 creates a three-dimensional shape of at least one subject on the side of the spindle 20. The subjects include at least the tool 22. In addition to the tool 22, for example, the tool holder 32, the spindle 20, the coolant nozzle 37, and the spindle head 24 may be included.

[0038] Specifically, upon receiving first and second images and first and second relative positions from the image acquisition unit 60, the shape generator 62 generates a three-dimensional shape of the subjects.

[0039] That is, the shape generator 62 determines a first relative distance D (see Fig. 3) between the first relative position and the second relative position. The first relative distance D is not the travel distance (the length of movement) by which the table 28 moves relative to the spindle 20 from the first relative position to the second relative position, but is the shortest distance between the first relative position and the second relative position.

[0040] Further, the shape generator 62 determines a plurality of points on at least the contour of the subjects included in one of the first and second images as feature points, and detects corresponding feature points corresponding to the determined feature points from the other of the first and second images.

[0041] By detecting the first relative distance D, the plurality of feature points, and their corresponding feature points, the shape generator 62 generates a three-dimensional shape (pre-processing shape or post-processing shape) based on the first relative distance D, the plurality of feature points, and their corresponding feature points. As a specific generation method, prior art methods can be used.

[0042] In this phase, after successfully generating a three-dimensional shape (pre-processing shape or post-processing shape), the shape generator 62 generates a success signal and outputs it to the control device 18. Furthermore, if the generation of a three-dimensional shape (pre-processing shape or post-processing shape) is successful, the shape generator 62 stores the successful three-dimensional shape (pre-processing shape or post-processing shape) in the storage unit 64.

[0043] On the other hand, if the successful generation of a three-dimensional shape (pre-processing shape or post-processing shape) has failed, the shape generator 62 generates a failure signal and outputs it to the control device 18.

[0044] Further, when the creation of a three-dimensional shape (pre-processing shape or post-processing shape) is unsuccessful, the shape creator 62 repeats the creation of the three-dimensional shape (pre-processing shape or post-processing shape).

[0045] Specifically, the shape generator 62 again sets a second relative distance D' different from the first relative distance D, and causes the image acquisition unit 60 to recapture the first and second images at respective positions spaced apart from each other by the second relative distance D'. Specifically, if the generation of the three-dimensional shape (pre-processing shape and post-processing shape) failed, the first relative distance D is changed (i.e., increased or decreased) to the second relative distance D', and the changed second relative distance D' is reported to the image acquisition unit 60.The image acquisition unit 60 acquires the first image and the second image again under a condition that the relative distance between the first relative position at which the camera 50 acquires the first image and the second relative position at which the camera 50 acquires the second image is equal to the second relative distance D', and outputs the first and second images to the shape generator 62.

[0046] Upon receiving the first and second images thus recaptured by the image acquisition unit 60, the shape generator 62 repeats the generation of a pre-processing shape based on the first and second images and the second relative distance D'. If the shape generator 62 fails to successfully generate a three-dimensional shape (pre-processing shape or post-processing shape) even after repeating the generation of the three-dimensional shape a predetermined number of times, it generates an abnormality signal and outputs it to the controller 18 and the annunciator 70.

[0047] The shape comparator 66 reads and compares the pre-processing shape and the post-processing shape stored in the storage unit 64, and outputs the comparison result to the state estimator 68. The state estimator 68 estimates the state of the post-processing shape based on the comparison result from the shape comparator 66.

[0048] Fig. Figure 4 is a conceptual diagram illustrating a comparison result between three-dimensional shapes. When the shape of the tool 22 before machining and the shape after machining are different, the different part, denoted by 22a, is extracted as a comparison result (difference) between the pre-machining shape and the post-machining shape.

[0049] When the part 22a that was not present in the pre-machining shape of the tool 22 is present in the post-machining shape of the tool 22, the state estimator 68 estimates that a cutting chip is adhered (attached) to the tool 22. When the part 22a that was present in the pre-machining shape of the tool 22 is not present in the post-machining shape of the tool 22, the state estimator 68 estimates that the tool 22 is worn. To estimate the state of the post-machining shape, the state estimator 68 generates a notification signal indicating that the estimated state should be notified and outputs the notification signal to the notifier 70.

[0050] The notifier 70 notifies the estimation result estimated by the state estimator 68. Specifically, the notifier 70 displays, for example, the pre-processing shape and the post-processing shape along with the comparison difference (difference) between the pre-processing shape and the post-processing shape on the display unit, and also displays the estimation result of the state estimator 68.

[0051] Upon receiving an anomaly signal from the shape generator 62, the detector 70 outputs a message indicating that a three-dimensional shape could not be created. Specifically, the detector 70 indicates on the display unit, for example, that a three-dimensional shape could not be created.

[0052] The detector 70 may include a display unit or may control an external display unit. The detector 70 may provide a message for display on the display unit by using a different notification method in addition to the previous notification method.

[0053] A process sequence of 3D shape generation in the processing system 10 is described below. Fig. 5 shows a flowchart illustrating a control sequence for 3D shape generation in the machining system 10. Upon receiving a machining command, the control device 18 begins with step S1. In step S1, the control device 18 executes a pre-machining mode for relatively moving the spindle 20 and the table 28 and outputs the position information corresponding to the relative movement to the 3D shape generation device 14. After completing the pre-machining mode, the control device 18 proceeds to step S2 and waits in step S2 until receiving a signal from the 3D shape generation device 14.

[0054] Upon receiving the position information from the control device 18, the 3D shape generating device 14 proceeds to step S11 to execute a pre-machining shape generating process.

[0055] At this stage, if the 3D generating device 14 fails to generate a pre-processing shape, it generates a failure signal and outputs it to the controller 18. Upon receiving the failure signal, the controller 18 returns to step S1 and executes the pre-processing mode again, outputting the position information to the 3D shape generating device 14. Upon receiving the position information, the 3D shape generating device 14 returns to step S11 to repeat the generation of a three-dimensional shape by executing the pre-processing shape generating process again.

[0056] If a pre-machining shape cannot be successfully created even after repeating the pre-machining shape creation a predetermined number of times, the 3D shape creation device 14 generates an abnormality signal and outputs it to the control device 18. At the same time, the device 14 reports the failure of creating a three-dimensional shape and terminates the pre-machining shape creation process. Upon receiving the abnormality signal, the control device 18 returns the spindle 20 and the table 28 to their original positions and terminates control of the machine tool body 16.

[0057] If the generation of the pre-machining shape is successful, the 3D shape generation device 14 stores the successfully generated pre-machining shape in the storage unit 64, generates a success signal, outputs it to the control device 18, and proceeds to step S12. Upon receiving the success signal, the control device 18 proceeds to step S3.

[0058] In step S3, the control device 18 executes the machining mode to move the spindle 20 and the table 28 relative to each other, thereby machining the workpiece into a predetermined shape. When the machining is completed, the control proceeds to step S4. In step S4, the control device 18 executes a post-processing mode to move the spindle 20 and the table 28 relative to each other and outputs the position information corresponding to the relative movement to the 3D shape generating device 14. Upon completion of the post-processing mode, the control device 18 proceeds to step S5 and waits until receiving a signal from the 3D shape generating device 14.

[0059] Upon receiving the position information from the control device 18, the 3D shape generating device 14 executes a post-processing shape generating process.

[0060] At this stage, if the 3D generating device 14 fails to generate a post-processing shape, it generates a failure signal and outputs it to the controller 18. Upon receiving the failure signal, the controller 18 returns to step S4 and executes the post-processing mode again, outputting the position information to the 3D shape generating device 14. Upon receiving the position information, the 3D shape generating device 14 returns to step S12 to repeat the post-processing shape generation by executing the post-processing shape generation process again.

[0061] However, if a post-processing shape cannot be successfully generated even after repeating the post-processing shape generation a predetermined number of times, the 3D shape generation device 14 generates an abnormality signal and outputs it to the control device 18. At the same time, the device 14 reports the failure of generating a three-dimensional shape and terminates the post-processing shape generation process. Upon receiving the abnormality signal, the control device 18 returns the spindle 20 and the table 28 to their original positions and terminates control of the machine tool body 16.

[0062] If the creation of the post-processing shape is successful, the 3D shape creation device 14 stores the successfully created post-processing shape in the storage unit 64, generates a success signal, outputs it to the control device 18, and terminates the post-processing shape creation process. Upon receiving the success signal, the control device 18 returns the spindle 20 and the table 28 to their original positions and terminates control of the machine tool body 16.

[0063] The following describes the previously described pre-processing shape generation process. The details of the previously described post-processing shape generation process are the same as those of the following pre-processing shape generation process; therefore, a description is omitted. Fig. 6 shows a flowchart illustrating the control sequence of the pre-machining shape generation process.

[0064] Upon receiving the position information from the control device 18, the image acquisition unit 60 proceeds to step S21. In step S21, the image acquisition unit 60 acquires the first image when the table 28 is located at the first relative position with respect to the spindle 20, and acquires the second image when the table 28 is located at the second relative position, based on the position information; then, control proceeds to step S22.

[0065] In step S22, the shape generator 62 generates a pre-processing shape based on the first and second images generated in step S21 and the first relative distance D between the first relative position at which the first image was acquired and the second relative position at which the second image was acquired.

[0066] In this phase, if the pre-machining shape has been successfully created, the shape generator 62 generates a success signal and outputs it to the control device 18, and the control proceeds to step S12 ( Fig. 5). On the other hand, if the shape generator 62 fails to generate the pre-processing shape, control proceeds to step S23, where it is determined whether the number of repetitions exceeds the predetermined number of times.

[0067] If the number of repetitions does not exceed the predetermined number of times, the shape generator 62 generates a failure signal and outputs it to the controller 18; then, control proceeds to step S24. In step S24, the shape generator 62 changes the relative distance between the first relative position at which the first image was acquired in step S21 and the second relative position at which the second image was acquired in step S21 from the first relative distance D to a second relative distance D'; then, control returns to step S21.

[0068] However, if the number of repetitions exceeds the predetermined number of times, the shape generator 62 proceeds to step S25. In step S25, the shape generator 62 generates an abnormality signal and outputs it to the notifier 70, thereby outputting a notification that the pre-processing shape could not be generated, and then terminates the pre-processing shape generation process.

[0069] The following describes the process flow of an estimation process of the 3D shape generating device 14. Fig. 7 shows a flowchart illustrating the control sequence of the estimation process. For example, when an estimation start command is received from the input unit and the pre-processing shape and the post-processing shape are stored in the storage unit 64, the 3D shape generation device 14 proceeds to step S31.

[0070] In step S31, the 3D shape generation device 14 reads the pre-processing shape and the post-processing shape from the storage unit 64, compares the read pre-processing shape and the post-processing shape, and proceeds to step S32. In step S32, the 3D shape generation device 14 estimates the state of the post-processing shape based on the comparison result obtained in step S31, then reports the estimated state to the operator in step S33, and then terminates the estimation process. [Modifications]

[0071] Although the foregoing embodiment has been described as an example of the present invention, the technical scope of the present invention is not limited to the scope described in the foregoing embodiment. The foregoing embodiment may, of course, be supplemented with various modifications or improvements. It will be understood from the description of the scope of the claims that forms with such modifications or improvements may be included within the technical scope of the invention.

[0072] Some of the modified or improved forms are described below as modifications. The same components as those described in the previous embodiment are denoted by the same reference numerals, and repeated explanations will be omitted. <Modifikation 1>

[0073] Fig. 8 is a schematic diagram illustrating a machining system 10A of Modification 1. In the machining system 10A of Modification 1, a camera 50A is disposed instead of the camera 50 of the previous embodiment. This camera 50A is for capturing the image of the side of the table 28 and is arranged to move with the spindle 20 relative to the table 28. In this embodiment, the camera 50A is disposed on a flank (i.e., side) of the spindle head 24 and captures images of the workpiece, the fixing jig for fixing the workpiece to the table 28, locking grooves 38, the table 28, etc. as subjects.

[0074] Further, in the case of the machining system 10A of Modification 1, a 3D shape generating device 14A is arranged instead of the 3D shape generating device 14 of the previous embodiment. Fig. 9 is a block diagram showing the configuration of the 3D shape generating device 14A. In the 3D shape generating device 14A, a shape generator 62A is arranged instead of the shape generator 62 in the previous embodiment, and a state estimator 68A is arranged instead of the state estimator 68 in the previous embodiment.

[0075] The mold generator 62A creates a three-dimensional shape of at least one subject on the side of the table 28. The subject includes at least one workpiece and includes, for example, the fastening jig, the locking groove 38, and the table 28 in addition to the workpiece.

[0076] Although the generation target of the three-dimensional shape in the shape generator 62A is different as described above, the method for generating the three-dimensional shape is the same as in the above-described embodiment, and therefore, a description is omitted.

[0077] The state estimator 68A estimates the state of the post-processing shape based on the comparison result from the shape comparator 66. Fig. Figure 10 shows a conceptual diagram illustrating a comparison result between three-dimensional shapes. When the shape of the workpiece W before machining and the shape after machining are different, the different part, denoted by Wa, is extracted as a comparison result (difference) between the pre-machining shape and the post-machining shape.

[0078] When a part that was present in the pre-processing shape of the workpiece W no longer exists in the post-processing shape of the workpiece W, the state estimator 68A estimates the no longer existing part Wa as a cutout or cut-out part. Further, in a case where a part that was not present in the pre-processing shape of the workpiece W is present in the post-processing shape of the workpiece W, the state estimator 68A estimates that a cutting chip is attached to the workpiece W. When estimating the state of the post-processing shape, the state estimator 68A generates a notification signal indicating that the estimated state should be notified and outputs the notification signal to the notifier 70.

[0079] In this way, according to the machining system 10A of Modification 1, a three-dimensional shape can be easily and accurately produced as in the machining system 10 of the previous embodiment. <Modifikation 2>

[0080] In the previous embodiment, the camera 50 for imaging the side of the spindle 20 is arranged on the table 28. However, as long as the camera 50 can move together with the table 28 with respect to the spindle 20, it may be arranged on a member or the like other than the table.

[0081] Likewise, in Modification 1, the camera 50A for imaging the side of the table 28 is arranged on the spindle head 24. However, as long as the camera 50A moves together with the spindle 20 with respect to the table 28, it may be arranged on a member or the like other than the spindle head 24. <Modifikation 3>

[0082] In the foregoing embodiment, the control device 18 of the machine tool 12 does not machine the workpiece based on the tool length and tool diameter of the tool 22 determined from the pre-machining shape or post-machining shape generated by the shape generator 62; but the control device 18 may be configured to machine the workpiece based on these factors.

[0083] In particular, for example, the control device 18 is configured to compensate the parameters for moving the spindle 20 and the table 28 relative to each other on the basis of the tool length and the tool diameter of the tool 22, determined from the pre-machining shape or post-machining shape of the tool 22 generated by the shape generator 62.

[0084] Thus, the machine tool 12 can machine a workpiece by using the tool length and the tool diameter of the tool 22 determined from the pre-machining shape or post-machining shape generated by the shape generator 62, whereby the machining accuracy of the workpiece can be improved.

[0085] Here, the tool length and tool diameter can be determined by calculation based on the three-dimensional shape. The calculation of the tool length and tool diameter can be performed by the 3D shape generation device 14 or the machine tool 12 (control device 18). <Modifikation 4>

[0086] Fig. 11 is a view illustrating a state in which the camera lens is colored with a dielectric working fluid. When the camera lens of the camera 50 is colored with a dielectric working fluid, a subject ST1 of the working fluid in a first image IM1 at the first relative position and a subject ST2 of the working fluid in a second image IM2 at the second relative position are arranged at substantially the same positions.

[0087] Therefore, the 3D shape generating device 14 may be configured such that, when there is no change in position between a subject ST1 in the first image IM1 acquired at the first relative position and a subject ST2 in the second image IM2 acquired at the second relative position, the device 14 recognizes the subjects as a spot on the camera lens of the camera 50 and reports this fact.

[0088] Similar to the 3D shape generating device 14, when there are subjects located at the same positions in the respective first image and second image, the 3D shape generating device 14A of Modification 1 may be configured to recognize the subjects as a spot on the camera lens of the camera 50A and report this fact. <Modifikation 5>

[0089] In the foregoing embodiment, when there is a part 22a extracted based on the (difference) as the result of the comparison between the pre-machining shape and the post-machining shape, the state estimator 68 estimates that a cutting chip is attached to the tool 22 or that the tool 22 is worn.

[0090] However, the state estimator 68 may also be configured to determine that a cutting chip is attached to the tool 22 or that the tool 22 is worn when the size of the part 22a extracted as a result of the comparison between the pre-machining shape and the post-machining shape is greater than or equal to a predetermined threshold. This configuration makes it possible to avoid a situation in which a warning is issued when a cutting chip attached to the tool 22 or a worn part of the tool 22 is not so large that it affects machining. <Modifikation 6>

[0091] The 3D shape generating device 14A of Modification 1 is configured to, when a part of the shape of the workpiece W before machining no longer exists on the post-machining shape of the workpiece W, estimate that the part is a cut-out or cut-out part and output a notification.

[0092] However, the 3D shape generation device 14A can also be configured to report the degree of similarity between the shape of the estimated cut or section part and the predetermined shape of the cut part, as previously stated. This configuration allows the operator to determine when maintenance is required on the machine tool 12 and when the tool 22 needs to be changed. <Modifikation 7>

[0093] In the previous embodiment, the image acquisition unit 60 is configured to acquire first and second images at arbitrary positions while the control device 18 moves the spindle 20 and the table 28 relative to each other from the predetermined start position to the predetermined end position. However, the image acquisition unit 60 may be configured to acquire the first image at the predetermined start position and the second image at the predetermined end position. In this case, when the shape generator 62 repeats the creation of the three-dimensional shape (pre-processing shape or post-processing shape), the control device 18 only needs to change the predetermined start position or the predetermined end position to change the relative distance from the first relative distance D to the different second relative distance D'. <Modifikation 8>

[0094] Fig.12 is a diagram illustrating a machining system 10B according to Modification 7. The machining system 10B of Modification 7 differs from the machining system 10 of the previous embodiment in that it includes a plurality of machine tools 12. Furthermore, the machining system 10B of Modification 7 differs from the machining system 10 of the previously described embodiment in that it includes a 3D shape generating device 14B for generating a three-dimensional shape of a part of each machine tool 12 instead of the 3D shape generating device 14.

[0095] Thus, the 3D shape generating device 14B generates a three-dimensional shape of a part of each machine tool 12, whereby the state, tendency, etc. of each machine tool 12 can be managed. <Modifikation 9>

[0096] In the above-described embodiment, the 3D shape generating device 14 is arranged separately from the control device 18, but it may be the control device 18. That is, the control device 18 may include the image acquisition unit 60, the shape generator 62, the shape comparator 66, the state estimator 68, and the detector 70 of the 3D shape generating device 14. This eliminates the need for a housing or the like of the 3D shape generating device 14, thus miniaturizing the system. <Modifikation 10>

[0097] The previous modifications 1 to 9 can be combined in any way as long as no inconsistencies occur. [Technical Ideas]

[0098] The following describes technical ideas that can be derived from the embodiment and modifications as described above.

[0099] The machining system (10, 10A, 10B) comprises a machine tool (12) and a 3D shape generating device (14, 14A, 14B) designed to generate a three-dimensional shape of a part of the machine tool (12).

[0100] The machine tool (12) comprises: a spindle (20) to which a tool (22) is attached; a table (28) configured to support a workpiece; a motor configured to drive a moving mechanism configured to move the spindle (20) and the table (28); and a camera (50, 50A) configured to move together with the table (28) with respect to the spindle (20) to capture an image of the side of the spindle (20), or to move together with the spindle (20) with respect to the table (28) to capture an image of the side of the table (28).

[0101] The 3D shape generating device (14, 14A, 14B) comprises: an image capturing unit (60) configured to capture a first image from the camera (50, 50A) when a relative position of the table (28) with respect to the spindle (20) is at a first relative position, and to capture a second image from the camera (50, 50A) when the relative position is at a second relative position different from the first relative position; and a shape generator (62, 62A) configured to generate a three-dimensional shape of at least one subject based on the first image, the second image, and a first relative distance (D) between the first relative position and the second relative position.

[0102] Since the camera (50) is configured to move together with the stage (28) relative to the spindle (20), or the camera (50A) is configured to move together with the spindle (20) relative to the stage (28), a three-dimensional shape of the subject can be accurately generated compared to a case where a camera that does not move relatively is used. In addition, a three-dimensional shape can be easily generated compared to a case where two cameras are used to generate a three-dimensional shape.

[0103] The 3D shape generating device (14, 14A, 14B) may further comprise: a shape comparator (66) configured to compare a pre-processing shape, which is the three-dimensional shape generated by the shape generator (62, 62A) before processing the workpiece, and a post-processing shape, which is the three-dimensional shape generated by the shape generator (62, 62A) after processing the workpiece; a state estimator (68, 68A) configured to estimate a state of the subject after processing based on the comparison result of the shape comparator (66); and a notifier (70) configured to notify the state estimated by the state estimator (68, 68A). This configuration enables the state of the machine tool (12) and other information to be reported to the operator through the state of the subject after processing.

[0104] In the machining system, the camera (50) may be configured to move together with the table (28) with respect to the spindle (20) to capture an image of the side of the spindle (20), the shape generator (62) may be configured to generate a three-dimensional shape of at least the tool (22), and the state estimator (68) may be configured to estimate that a chip is attached to the tool (22) when a part (22A) that was not present in the pre-machining shape of the tool (22) is present in the post-machining shape of the tool (22), and to estimate that the tool (22) is worn when a part (22a) that was present in the pre-machining shape of the tool (22) has disappeared from the post-machining shape of the tool (22). This configuration makes it possible to provide an operator with a means of changing the tool (22) and to report the status of the machine tool (12) and other information to the operator.

[0105] In the machining system, the camera (50A) may be configured to move together with the spindle (20) with respect to the table (28) to capture an image of the side of the table (28), the shape generator (62A) may be configured to generate a three-dimensional shape of at least the workpiece, AND the state estimator (68A) may be configured to estimate that a chip is attached to the workpiece when a part that was not present in the pre-machining shape of the workpiece is present in the post-machining shape of the workpiece, and to estimate, when a part that was present in the pre-machining shape of the workpiece has disappeared from the post-machining shape of the workpiece, that the disappeared part is a cut-off part. This configuration enables the state of the machine tool (12) and other information to be reported to the operator through the state of the workpiece.

[0106] In the machining system, the camera (50) may be configured to move together with the table (28) with respect to the spindle (20) to capture an image of the side of the spindle (20), the shape generator (62) may be configured to generate a three-dimensional shape of at least the tool (22), and the machine tool (12) may be configured to machine the workpiece by using the tool length and the tool diameter of the tool (22) acquired from the three-dimensional shape of the tool (22) generated by the shape generator (62). This makes it possible to improve the machining accuracy of the workpiece.

[0107] In the machining system, when the three-dimensional shape cannot be created, the shape generator (62, 62A) can repeat the creation of the three-dimensional shape based on a second relative distance (D') different from the first relative distance (D) and the first image and second image acquired by the image acquisition unit (60) at the first relative position and the second relative position, respectively, which are spaced from each other by the second relative distance (D'). Therefore, even in a case where a three-dimensional shape cannot be created due to a temporary error or the like, this configuration enables the creation of a three-dimensional shape after eliminating the error or the like.

[0108] The machining system (10B) may include a plurality of machine tools (12), and the 3D shape generating device (14B) may be configured to generate a three-dimensional shape of a part of each of the machine tools (12). This enables the management of the states, tendencies, etc., of individual machine tools (12).

[0109] The 3D shape generation device (14, 14A) can be a control device (18) of the machine tool (12). This makes it possible to dispense with the housing or the like of the 3D shape generation device (14, 14A), thus miniaturizing the system.

Claims

[1] Machining system (10, 10A, 10B) comprising a machine tool (12) and a 3D shape generating device (14, 14A, 14B) configured to generate a three-dimensional shape of a part of the machine tool (12), wherein the machine tool (12) comprises: a spindle (20) to which a tool (22) is attached; a table (28) adapted to support a workpiece; a motor configured to drive a movement mechanism configured to move the spindle (20) and the table (28); and a camera (50, 50A) designed to move together with the table (28) with respect to the spindle (20) to take an image of the side of the spindle (20), or to move together with the spindle (20) with respect to the table (28) to take an image of the side of the table (28), the 3D shape generating device (14, 14A, 14B) comprises: an image capture unit (60) configured to capture a first image from the camera (50, 50A) when a relative position of the table (28) with respect to the spindle (20) is at a first relative position, and to capture a second image from the camera (50, 50A) when the relative position is at a second relative position different from the first relative position; and a shape generator (62, 62A) configured to generate a three-dimensional shape of at least one subject based on the first image, the second image and a first relative distance (D) between the first relative position and the second relative position. [2] A processing system according to claim 1, wherein: the 3D shape generating device (14, 14A, 14B) further comprises: a shape comparator (66) configured to compare a pre-processing shape, which is the three-dimensional shape generated by the shape generator (62, 62A) before processing the workpiece, and a post-processing shape, which is the three-dimensional shape generated by the shape generator (62, 62A) after processing the workpiece; a state estimator (68, 68A) configured to estimate a state of the subject after processing on the basis of the comparison result from the shape comparator (66); and a reporter (70) configured to report the state estimated by the state estimator (68, 68A). [3] Processing system according to claim 2, wherein: the camera (50) is adapted to move together with the table (28) with respect to the spindle (20) to capture an image of the side of the spindle (20); the shape generator (62) is designed to produce a three-dimensional shape of at least the tool (22); and the state estimator (68) is configured to estimate that a chip is attached to the tool (22) when a part (22A) that was not present in the pre-machining shape of the tool (22) is present in the post-machining shape of the tool (22), and to estimate that the tool (22) is worn when a part (22a) that was present in the pre-machining shape of the tool (22) has disappeared from the post-machining shape of the tool (22). [4] A processing system according to claim 2, wherein: the camera (50A) is adapted to move together with the spindle (20) with respect to the table (28) to capture an image of the side of the table (28); the shape generator (62A) is designed to produce a three-dimensional shape of at least the workpiece; and the state estimator (68A) is configured to estimate that a chip is attached to the workpiece when a part that was not present in the pre-machining shape of the workpiece is present in the post-machining shape of the workpiece, and to estimate, when a part that was present in the pre-machining shape of the workpiece has disappeared from the post-machining shape of the workpiece, that the disappeared part is a cut-off part. [5] A processing system according to claim 1, wherein: the camera (50) is adapted to move together with the table (28) with respect to the spindle (20) to capture an image of the side of the spindle (20); the shape generator (62) is designed to produce a three-dimensional shape of at least the tool (22); and the machine tool (12) is designed to machine the workpiece by using a tool length and a tool diameter of the tool (22) detected by the three-dimensional shape of the tool (22) generated by the shape generator (62). [6] Processing system according to one of claims 1 to 5, wherein: if the three-dimensional shape cannot be generated, the shape generator (62, 62A) repeats the generation of the three-dimensional shape on the basis of a second relative distance (D') different from the first relative distance (D) and the first image and second image acquired by the image acquisition unit (60) at the first relative position and the second relative position, respectively, the first relative position and the second relative position being spaced from each other by the second relative distance (D'). [7] Processing system according to one of claims 1 to 6, wherein: the machining system (10B) comprises a plurality of machine tools (12); and the 3D shape generating device (14B) is configured to generate a three-dimensional shape of a part of each of the machine tools (12). [8] Machining system according to one of claims 1 to 6, wherein the 3D shape generating device (14, 14A) is a control device of the machine tool (12).

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