PROCESSING EVALUATION DEVICE, PROCESSING SYSTEM AND PROCESSING EVALUATION PROCEDURE

Abstract

Machining evaluation device (20a) evaluating a component shape of a component formed by a mechanical device that performs machining on a workpiece by driving an axis, wherein the machining evaluation device (20a) includes: a machining tolerance setting unit (100) that sets a machining tolerance and a design value, wherein the machining tolerance is a tolerance of a machining defect for each specified part, which is a part specified among parts contained in the component after a machining program controlling the machining is executed; a machining simulation execution unit (101a) that performs a machining simulation of the machining using a machine model simulating a property of the mechanical device and a machining program (42);and a first machining result evaluation unit (102) that calculates a partial machining defect (48S) for each specified part based on a simulation shape (47S) and the design value, wherein the simulation shape (47S) is predicted by the machining simulation and is the component shape after the machining program is executed, wherein the partial machining defect (48S) is a predicted value of a machining defect of the simulation shape.

Description

Area

[0001] The present disclosure relates to a machining evaluation device, a machining system and a machining evaluation method for evaluating a predicted shape of a component formed by machining by a mechanical device. background

[0002] A mechanical device that performs work using multi-degree-of-freedom motion, such as a numerically controlled machine tool and an industrial robot, incorporates a multitude of axes to achieve multi-degree-of-freedom motion and a multitude of servo drives to power the axes. Such a mechanical device achieves multi-degree-of-freedom motion by controlling the position of an object for each axis and synchronously controlling the movement of the axes. For example, a mechanical device machining a workpiece—the object being machined to form a component—machines the workpiece while simultaneously driving various objects to be powered, such as a tool used to perform the machining and the workpiece itself, via axes.When such a mechanical device processes the workpiece, the component, which is a finished product, may exhibit a defect in its shape due to characteristics of the mechanical device or similar factors. Therefore, it is desirable to accurately assess the defect in the machined shape.

[0003] A toolpath display device from patent literature 1 similarly displays tool vectors representing the position of a tool as obtained from each of at least two paths: a program path, a command path, and an actual path. The program path is a path of a tool tip corresponding to a machining program; the command path is a path of the tool tip corresponding to a command signal to a machine tool; and the actual path is a path of the tool tip detected by a sensing device. The toolpath display device thus visually indicates a defect in a machined shape to an operator and enables the operator to identify the cause of a failure. List of quotations Patent literature

[0004] Patent literature 1: Japanese publication no. 2013-257809 Brief description of the technical problem

[0005] However, with the above technique from patent literature 1, a problem arose that, in the case of a component which has a different tolerance with regard to machining accuracy for each part, a machining error in a predicted form cannot be evaluated for each part of the component.

[0006] The present disclosure was prepared in light of the foregoing, and one object of the present disclosure is to provide a machining evaluation device that can evaluate a machining defect in a predicted form for each part of a component, which has a different tolerance with respect to machining accuracy for each part. Solution to the problem

[0007] To solve the aforementioned problems and fulfill the task, a machining evaluation device according to the present disclosure evaluates a component shape formed by a mechanical device that performs machining on a workpiece by driving an axis. The machining evaluation device includes a machining data setting unit for setting a machining tolerance and a design value, wherein the machining tolerance is a tolerance of a machining defect for each specified part, which is a part defined among the parts contained in the component after a machining program controlling the machining has been executed.Furthermore, the machining evaluation device includes: a machining simulation execution unit to perform a machining simulation of the machining process using a machine model that simulates a property of the mechanical device and the machining program; and a first machining result evaluation unit to calculate a simulation machining error for each of the specified part based on a simulation shape and the design value, wherein the simulation shape is predicted by the machining simulation and is the component shape after the machining program is executed, and wherein the simulation machining error is a predicted value of a machining error of the simulation shape. Advantageous effects of the invention

[0008] The machining evaluation device according to the present disclosure has an effect such that it is able to evaluate the machining error in the predicted form for each part of the component, which has a different tolerance with respect to machining accuracy for each part. Short description of the drawings Fig. Figure 1 is a representation illustrating an example of a configuration of a numerically controlled machine tool included in a machining system according to a first embodiment. Fig. Figure 2 is a schematic representation to illustrate a configuration of an X-axis drive unit included in the machine tool with numerical control according to the first embodiment. Fig. Figure 3 is a block diagram illustrating an example of a configuration of a servo control unit according to the first embodiment. Fig. Figure 4 is a block diagram illustrating an example of a process control configuration according to the first embodiment. Fig. Figure 5 is a block diagram illustrating an example of a hardware configuration of the machining system that includes a machining evaluation device according to the first embodiment. Fig. Figure 6 is a block diagram illustrating an example of a configuration of the machining evaluation device included in the machining system according to the first embodiment. Fig. Figure 7 is a flowchart illustrating a machining operation for machining evaluation by the machining system according to the first embodiment. Fig. Figure 8 is a representation to illustrate examples of a design value and a machining tolerance for each part of a component that is evaluated by the machining evaluation device according to the first embodiment. Fig. Figure 9 is a block diagram illustrating an example of a configuration of a machining simulation execution unit included in the machining evaluation device according to the first embodiment. Fig. Figure 10 is a representation to illustrate examples of a partial machining error output by the machining evaluation device according to the first embodiment. Fig. Figure 11 is a representation illustrating an example of a case in which a processing circuit implementing the machining evaluation device of the machining system according to the first embodiment includes a processor and a memory. Fig. Figure 12 is a representation illustrating an example of a case in which a processing circuit implementing the processing evaluation device according to the first embodiment includes dedicated hardware. Fig. Figure 13 is a block diagram illustrating an example of a configuration of a machining evaluation device included in a machining system according to a second embodiment. Fig. Figure 14 is a representation illustrating an example of a two-dimensional CAD drawing that is entered into the machining evaluation device according to the second embodiment. Fig. Figure 15 is a block diagram illustrating an example of a configuration of a machining simulation execution unit included in the machining evaluation device according to the second embodiment. Fig. Figure 16 is a block diagram illustrating an example of a configuration of a machining evaluation device included in a machining system according to a third embodiment. Fig. Figure 17 is a block diagram illustrating an example of a configuration of a machining evaluation device included in a machining system according to a fourth embodiment. Fig. Figure 18 is a block diagram illustrating an example of a configuration of a machining evaluation device included in a machining system according to a fifth embodiment. Fig. Figure 19 is a block diagram illustrating an example of a configuration of a machining evaluation device included in a machining system according to a sixth embodiment. Fig. Figure 20 is a block diagram illustrating an example of a hardware configuration of the machining system that includes the machining evaluation device according to the sixth embodiment. Fig. Figure 21 is a block diagram illustrating an example of a configuration of a machining evaluation device included in a machining system according to a seventh embodiment. Fig. Figure 22 is a block diagram illustrating an example of a hardware configuration of the machining system that includes the machining evaluation device according to the seventh embodiment. Description of embodiments

[0009] A machining evaluation device, a machining system, and a machining evaluation method according to embodiments of the present disclosure are described in more detail below with reference to the drawings. It should be noted that each embodiment described below specifically describes a machining evaluation device that evaluates a predicted shape of a component formed by a numerically controlled machine tool, which is an example of a mechanical device that machines a workpiece; however, the present disclosure is not limited to the configuration described in each embodiment.The machining system, which includes the machining evaluation device described in each embodiment, is applicable not only to the numerically controlled machine tool, but also to various mechanical devices, such as an industrial machine and an industrial robot, which perform work by driving a multitude of axes. First embodiment.

[0010] Fig. Figure 1 is a representation illustrating an example of a numerically controlled machine tool configuration included in a machining system according to a first embodiment. A numerically controlled machine tool 99, included in the machining system (a machining system 1a to be described later), is a device that controls a machine tool by means of numerical control and forms a component (a component 7 to be described later) by machining a workpiece 78, i.e., a workpiece to be machined. The machining system 1a includes a machining evaluation device (a machining evaluation device 20a to be described later) which predicts and evaluates the shape of the component 7 formed by the machining performed by the numerically controlled machine tool 99.

[0011] It should be noted that in the following description, two axes that are perpendicular to each other in a plane, running parallel to an upper surface of a worktable 77 contained in the numerically controlled machine tool 99, or to an upper surface of component 7, are defined as an X-axis and a Y-axis. Furthermore, an axis that runs perpendicular to the X-axis and the Y-axis is defined as a Z-axis.

[0012] The machine tool 99 with numerical control according to the first embodiment is a vertical three-axis cutting machine. The machine tool 99 with numerical control includes an X-axis drive unit 93X, which contains a servo controller that drives the X-axis, a Y-axis drive unit 93Y, which contains a servo controller that drives the Y-axis, a Z-axis drive unit 93Z, which contains a servo controller that drives the Z-axis, and a spindle control unit 94, which contains a process control 5 (to be described later) that controls a spindle 83.

[0013] Servo control is a device that uses a position detector to detect the position of a control target and performs feedback control using an actuator such that the position of the control target coincides with a command position, the actuator comprising an electric motor, such as a rotary motor, a linear motor or a voice coil motor, a hydraulic cylinder, a pneumatic cylinder or a piezoelectric element.

[0014] The machine tool 99 with numerical control drives a tool 76 in the directions of the X-axis and the Z-axis, drives the workpiece 78 placed on the worktable 77 in the direction of the Y-axis and rotates the tool 76 using the spindle 83 to machine the workpiece 78.

[0015] The work performed by the numerically controlled machine tool 99 consists of driving axes according to a machining program 42 and achieving the shape of the component 7 formed from the workpiece 78 by cutting. Whether the shape of the component 7 formed from the workpiece 78 meets a predetermined standard or not, in particular whether the pre-designed form accuracy and surface accuracy are met or not, determines whether the work of the numerically controlled machine tool 99 is performed correctly or not.

[0016] In the numerically controlled machine tool 99, a rotary motion of a motor 71, acting as the actuator, is converted into a linear motion in the drive direction of each axis by a feed spindle 73. The rotary motion is supported by a guide mechanism 72, and the axis thus has only one degree of freedom in the feed direction of the feed spindle 73. Consequently, the numerically controlled machine tool 99 combines the linear motions in the axes to achieve a movement of the tool 76 in two degrees of freedom in an XZ plane and a movement of the workpiece 78 in one degree of freedom in the Y direction, thereby achieving movement in a three-dimensional space of X, Y, and Z, or in three degrees of freedom.The numerically controlled machine tool 99 uses the spindle 83 to rotate the tool 76 and removes material from a section of the workpiece 78 that interacts with the tool 76, thereby forming a three-dimensional machined shape of the component 7.

[0017] Next, the X-axis drive unit 93X, the Y-axis drive unit 93Y, and the Z-axis drive unit 93Z, which are included in the numerically controlled machine tool 99, are described. In the first embodiment, the X-axis drive unit 93X is described as an example; however, the Y-axis drive unit 93Y and the Z-axis drive unit 93Z have similar configurations. It should be noted, however, that the control target for the X-axis and the Z-axis is the tool 76, whereas the control target for the Y-axis is the workpiece 78.

[0018] Fig. Figure 2 is a schematic representation illustrating a configuration of the X-axis drive unit included in the numerically controlled machine tool according to the first embodiment. As shown in Fig. As illustrated in Figure 2, the numerically controlled machine tool 99 includes a command value calculation unit 9, the process control 5, a servo control 95X, and a mechanical fixture unit 96. The mechanical fixture unit 96 includes a drive mechanism 97X and a mechanical structure 98. The command value calculation unit 9, the servo control 95X, and the drive mechanism 97X form the X-axis drive unit 93X. The servo control 95X includes a servo control unit 6a. It should be noted that the numerically controlled machine tool 99 further includes a servo control 95Y and a drive mechanism 97Y, which form the Y-axis drive unit 93Y, as well as a servo control 95Z and a drive mechanism 97Z, which form the Z-axis drive unit 93Z, as shown in Figure 2. Fig. 2 are not illustrated.

[0019] A mechanism comprising a roller for converting the rotary motion of the motor 71 in the X-axis into linear motion and a roller for supporting this conversion is the drive mechanism 97X. In the X-axis drive unit 93X, the rotary motion of the motor 71 is transmitted to the feed spindle 73 via a coupling 74 and converted into linear motion via a nut 81 and a reduction gear 79. The linear motion of the feed spindle 73 is limited by support bearings 75a and 75b. The linear motion of the nut 81 drives the tool 76 in the X-axis direction via the mechanical structure 98 for the X-axis, which is related to the Z-axis, a support element, and the like, arranged between the tool 76 and the nut 81. Furthermore, the area of ​​the mechanical structure 98 varies depending on the axis.For example, the drive mechanism 97Z for the Z-axis has no role in converting the motion of the motor 71 in the X-axis when viewed from the X-axis and is therefore included in the mechanical structure 98 for the X-axis.

[0020] A position command Xc for the X-axis is issued by the command value calculation unit 9 and input into the servo control unit 6a. The position command Xc is calculated by the command value calculation unit 9 according to the machining program 42 and specifies the position of an object to be driven in a desired control state. The servo control unit 6a performs feedback control to reduce any error between a detected position Xd and the position command Xc and outputs a motor current Ix to the motor 71 to drive the drive mechanism 97X. The detected position Xd is obtained by multiplying a rotation angle of the motor 71, detected by a rotation angle detector 2 attached to the motor 71, by the thread pitch of the feed spindle 73. The drive mechanism 97X is connected to the mechanical structure 98, which contains the tool 76, i.e., the control target.Although the rotary angle detector 2 here only detects the rotation angle of the motor 71, the rotary motion and the linear motion can readily be converted into one another, as described above. Therefore, the rotary angle detector 2 can multiply the rotation angle of the motor by the thread pitch of the feed spindle 73 and output the detected position Xd, which has been converted into the linear motion of the servo controller 95X for the X-axis. The rotary angle detector 2 is an example of a position detector attached to the motor 71, i.e., a detection point, and outputs the detected position Xd.

[0021] In a case where the numerically controlled machine tool 99 is a cutting machine, the command value calculation unit 9 outputs a spindle speed command to the process control 5 as a process command. The process control 5 controls the spindle 83 based on the spindle speed command.

[0022] Fig. Figure 3 is a block diagram illustrating an example of a servo control unit configuration according to the first embodiment. The servo control unit 6a uses the position command Xc, input by the command value calculation unit 9, and the detected position Xd, input by the rotary angle detector 2, to calculate the motor current Ix and outputs the motor current Ix to the motor 71. First, an adder / subtractor 61a calculates a position deviation (Xc-Xd), i.e., a difference between the position command Xc and the detected position Xd. A position controller 62 performs position control according to the position deviation (Xc-Xd) and generates a speed command Vc. An example of the position controller 62 is a proportional (P) controller. A speed calculator 65 generates a detected speed Vd from the detected position Xd, output by the rotary angle detector 2.An example of the speed calculator 65 is a differential calculator. An adder / subtractor 61b calculates a speed deviation Vde = Vc - Vd, i.e., a difference between the speed command Vc and the detected speed Vd. A speed controller 63 performs speed control according to the speed deviation Vde and generates a current command Ic. An example of the speed controller 63 is a proportional-integral (PI) controller. An adder / subtractor 61c calculates a current deviation (Ic - Ix), i.e., a difference between the current command Ic and the motor current Ix, which is output by a current controller 64. Finally, the current controller 64 performs current control according to the current deviation (Ic - Ix) and outputs the motor current Ix. An example of the current controller 64 is a PI controller.

[0023] The servo control unit 6a has gains in the aforementioned P controller and PI controller, which are set as parameters, and can change the behavior of the servo control 95X by adjusting the parameters.

[0024] The spindle control unit 94 contains the process control 5. Fig. Figure 4 is a block diagram illustrating an example of a process control configuration according to the first embodiment. The process control 5, which controls the spindle 83, is implemented in a spindle unit or spindle amplifier that controls a spindle motor. The process control 5 performs feedback control for the speed and torque of the spindle 83 according to a rotation command issued by the spindle 83. The process control 5 receives the process command as input, performs control using process feedback, and outputs a process variable. In a case where the numerically controlled machine tool 99 is a cutting machine, the process command is the spindle speed command (the speed command Vc), and the process variable is a spindle current (the motor current Ix). The process feedback is the rotation angle (the detected position Xd) measured by the rotation angle detector 2 of the spindle 83.The difference between the process control unit 5 and the servo control unit 6a is that the process control unit 5 does not include the position control unit 62 and receives the speed command Vc, i.e., the spindle speed command. However, when performing position control on the spindle 83, the process control unit 5 can have the same control structure as the servo control unit 6a, with the spindle rotation angle as the process command.

[0025] As described above, the servo control unit 6a performs control via feedback control such that the detected position Xd coincides with the position specified by the position command Xc, and the process control unit 5 performs control such that the detected rotational speed Vd, calculated from the detected position Xd, coincides with the rotational speed command Vc, i.e., the spindle speed command. However, even with feedback control, an error can occur between the tip position of the tool 76 and a machining point on the workpiece 78 during machining, which can result in material not being cut or being excessively cut in the workpiece 78, leading to a machining defect. For example, because the rotary angle detector 2 cannot be located at the position corresponding to the tip of the tool 76, i.e.,The control target is aligned with the tool. In a case where a disturbance occurs at the control target that cannot be detected by the rotation angle detector 2, or in a case where the feedback control of the servo control unit 6a cannot follow the input of the disturbance, an error occurs in the movement of the tool 76. Examples of the cause of such a disturbance include vibration of the coupling 74, the feed spindle 73, the guide mechanism 72, the mechanical structure 98, and the like, an error due to a frictional force, and the like.These disturbances are known to vary depending on the position of another axis located between the tool 76 and the nut 81, the mass of the tool 76 and the workpiece 78, aging of the mechanical fixture unit 96, wear of the feed spindle 73 and the nut 81, the amount of lubricating oil on each moving axis, changes in air temperature, variations in assembly at the time of manufacture, and the like. Furthermore, during cutting, depending on a combination of the number of revolutions of the tool 76, the cutting depth per revolution, and the cutting depth in the axial direction of the tool 76, a self-excited vibration, known as chatter, is generated between the tool 76 and the workpiece 78. In this case, the generation of chatter causes the tool 76 and the workpiece 78 to vibrate, resulting in a machining defect.

[0026] If the machining error occurs as described above, causing deviations from the design-specified dimensional and surface accuracy, the work is ultimately defective, and the component 7 formed from workpiece 78 must be discarded or subjected to corrective machining. This leads to problems such as increased scrap and decreased productivity due to increased machining time. Therefore, it is preferable to predict the machining accuracy to be achieved in advance, and if the target machining accuracy cannot be achieved, to modify a working condition to one that allows the target to be reached. The working condition is modified, for example, by adjusting the machining program 42 or a parameter used for feedback control.

[0027] Fig. Figure 5 is a block diagram illustrating an example of a hardware configuration of the machining system, which includes the machining evaluation device according to the first embodiment. The machining system 1a, which includes the machining evaluation device 20a, a simulation device, comprises the numerically controlled machine tool 99, a computer 23, and a network hub 24 that connects the two. The numerically controlled machine tool 99 performs the machining according to the machining program 42. The machining evaluation device 20a, which simulates the characteristics of the numerically controlled machine tool 99 and executes the simulation according to the machining program 42, is implemented as software in the computer 23. The network hub 24 connects the machining evaluation device 20a and the numerically controlled machine tool 99.However, multiple numerically controlled machine tools 99 can be present in the same network, as can multiple computers 23 on which the respective machining evaluation devices 20a are implemented. Alternatively, at the network hub 24, to which multiple numerically controlled machine tools 99 are connected, a unit of computer 23 can contain multiple machining evaluation devices 20a corresponding to the respective numerically controlled machine tools 99. Furthermore, the network hub 24 can be connected to the computer 23 and the numerically controlled machine tool 99 via a wired cable or via a wireless network.Alternatively, the computer 23 and the numerically controlled machine tool 99 can be directly connected without the network hub 24; the machining evaluation device 20a can be implemented in a computer used for control by the numerically controlled machine tool 99; or the computer 23 can be implemented on a computer, server, or in the cloud at a remote location. Furthermore, the functions implemented by the machining evaluation device 20a can be distributed and placed on multiple computers connected to a network.

[0028] Fig. Figure 6 is a block diagram illustrating an example configuration of the machining evaluation device included in the machining system according to the first embodiment. It should be noted that in Fig. 6. The illustration of the computer 23, the network hub 24, and the numerically controlled machine tool 99, which are included in the machining system 1a, has been omitted. The machining evaluation device 20a included in the machining system 1a comprises a machining tolerance setting unit 100, i.e., a machining data setting unit, a machining simulation execution unit 101a, and a first machining result evaluation unit 102.

[0029] The machining tolerance setting unit 100 receives a component shape 41, which is entered externally and specifies a component shape after execution of the machining program 42. The component shape 41 contains shapes for a multitude of parts.

[0030] The machining tolerance setting unit 100 also receives part information 40, which is entered by a system user, such as an operator, where the part information 40 represents a design value and a machining tolerance with respect to the dimension of each part of component 7 and a design value and a machining tolerance with respect to the surface accuracy of each part of component 7. The machining tolerance with respect to dimension and surface accuracy is a tolerance with respect to a machining defect for each part.

[0031] Machining system 1a allows the system user to enter the part information 40 (the design value and machining tolerance) for each part into the machining tolerance setting unit 100, while the component shape 41 is displayed on a display device (not illustrated) or the like. The system user specifies a part in component 7 and enters the part information 40 into the machining tolerance setting unit 100, so that the machining tolerance setting unit 100 associates the shape of the part with its design value and machining tolerance. The machining tolerance setting unit 100 sends information, including the shape, design value, and machining tolerance set for each part, to the first machining result evaluation unit 102 as part setting information 46.

[0032] The machining simulation execution unit 101a receives machine model information 45 from an external source, which simulates the properties of the numerically controlled machine tool 99, the machining program 42 used for machining, tool information 43, which represents information about the tool 76 used for machining, and workpiece information 44, which represents information about the workpiece 78, i.e., a workpiece to be machined. Based on the received information, the machining simulation execution unit 101a calculates a simulation shape 47S, i.e., a shape of component 7 that is formed after machining using the numerically controlled machine tool 99 and is a predicted shape of component 7. The machining simulation execution unit 101a sends the simulation shape 47S as a calculated result to the first machining result evaluation unit 102.

[0033] The first machining result evaluation unit 102 receives the part setting information 46 from the machining tolerance setting unit 100 and receives the simulation form 47S from the machining simulation execution unit 101a.

[0034] The first machining result evaluation unit 102 calculates a machining defect predicted by simulation for each specified part. That is, the first machining result evaluation unit 102 uses the part setting information 46 set by the machining tolerance setting unit 100 and the simulation form 47S calculated by the machining simulation execution unit 101a to calculate a part machining defect 48S, i.e., the simulation machining defect. Specifically, the first machining result evaluation unit 102 uses the part setting information 46 and the simulation form 47S to calculate, for each part for which the machining tolerance is set, the dimensional accuracy or surface roughness of that part in the simulation form 47S. The first machining result evaluation unit 102 calculates the part machining defect 48S for each part.a difference between the shape of the part, which includes the dimensional accuracy obtained through the machining simulation or the surface roughness, and the design value of the part. After calculating the partial machining error 48S for each part, the first machining result evaluation unit 102 plots the partial machining error 48S for each part on a three-dimensional model of component 7 as a machined object (a plate gauge 80 in the first embodiment).

[0035] Next, a processing procedure for processing evaluation by the processing system 1a is described. Fig. Figure 7 is a flowchart illustrating the machining process for machining evaluation by the machining system according to the first embodiment. Fig. Section 7 describes a machining evaluation process that includes simulating the machined shape using machining system 1a. Simulating the machined shape is part of the machining preparation.

[0036] A system user, such as a designer, uses a design unit to design component 7, which is to be machined by the numerically controlled machine tool 99 (step S1). Specifically, the design unit, which contains computer-aided design (CAD) software capable of creating a three-dimensional component shape, designs component 7, which is to be machined, according to instructions from the system user. The design unit designs component 7 to create component shape 41, which will be the component shape after the machining program 42 is executed.

[0037] The system user determines the tool 76 to be used for forming component 7 and the workpiece 78 to be machined (step S2). Specific information about the workpiece 78 includes details about its material, its dimensions before machining, the method for gripping the workpiece 78 during machining, and the like. The specific information about the tool 76 is tool information 43, and the specific information about the workpiece 78 is workpiece information 44.

[0038] The system user creates the machining program 42 using a programming device (step S3). Specifically, the programming device creates the machining program 42 according to an instruction from the system user. The machining program 42 created by the programming device is the machining program 42 for the numerically controlled machine tool 99 to machine the component 7 designed in step S1. The machining program 42 is created based on the three-dimensional component shape 41 (machined shape) of the component 7 designed in step S1 and the information about the tool 76 and the workpiece 78 determined in step S2, and is described in a language known as Electronic Industries Alliance (EIA) code or G-code.Machining program 42 describes three-dimensional coordinates that define a path to be traversed by the tool 76 during machining, a command rotational speed of the tool 76 at the time of traversing the path, and a rotational speed of the tool 76 at the time of traversing the path. Machining program 42 is often created using computer-aided manufacturing (CAM) software, where the CAM software automatically generates and outputs a machining program, such as machining program 42, when the necessary conditions are set. Alternatively, machining program 42 can be created using interactive programming software, which constructs the machined shape using an interactive dialog, generates a command path described in EIA code or G-code, and outputs the command path.The programming device outputs the created editing program 42.

[0039] The design unit inputs the component shape 41, which represents the component shape after the machining program 42 is executed, into the machining tolerance setting unit 100. Furthermore, the machining tolerance setting unit 100 sets the design value and machining tolerance for each part of component 7 according to an instruction from the system user (step S4). In particular, the machining tolerance setting unit 100 sets the design value and machining tolerance for the dimension of the part of component 7 and the design value and machining tolerance with respect to the surface accuracy of the part of component 7, according to an instruction from the system user.

[0040] It should be noted that the machining tolerance setting unit 100, instead of the component shape 41, which represents the constructed component shape, can receive a component shape after execution of the machining program 42, which is output by the CAM software when the machining program 42 is created in step S3. The component shape after execution of the machining program 42, output by the CAM software, is a three-dimensional shape model that reflects the expected uncut sections and surface roughness when the tool 76 follows an ideal path according to the machining program 42.Furthermore, depending on the CAM software, the output machining program 42 can contain a variety of machining steps, such as roughing, semi-roughing, and finishing, to achieve the final component shape. This allows the machining tolerance setting unit 100 to set different design values ​​and machining tolerances for the respective machining steps. The machining tolerance setting unit 100 sends the information, including the set design value and machining tolerance for each part, to the first machining result evaluation unit 102 as the part setting information 46.

[0041] The machining simulation execution unit 101a performs a machining simulation using the machine model information 45, the machining program 42, the tool information 43 and the workpiece information 44, which are entered from outside (step S5).

[0042] The machining simulation execution unit 101a performs the machining simulation to calculate the simulation shape 47S, i.e., the shape of component 7 formed after machining by the numerically controlled machine tool 99. In other words, the machining simulation execution unit 101a obtains the simulation shape 47S as a result of the simulation, i.e., data on the component shape obtained through machining. The machining simulation execution unit 101a sends the simulation shape 47S as a calculated result to the first machining result evaluation unit 102.

[0043] The first machining result evaluation unit 102 receives the part setting information 46, sent by the machining tolerance setting unit 100, and the simulation form 47S, sent by the machining simulation execution unit 101a. Based on the part setting information 46 and the simulation form 47S, the first machining result evaluation unit 102 calculates the dimension and surface accuracy of each part. For each part, the first machining result evaluation unit 102 calculates the machining error, which is a simulation result and represents the difference between the dimension and surface accuracy of each part and its corresponding design value. That is, the first machining result evaluation unit 102 calculates the part machining error 48S for each part as the machining error predicted by the simulation (step S6).

[0044] The first machining result evaluation unit 102 outputs the calculated partial machining error 48S to the outside from the machining evaluation device 20a as an evaluation result (step S7).

[0045] Here, an example of the component shape 41 and the part information 40 used by the machining evaluation device 20a is described. Fig. Figure 8 is a diagram illustrating examples of the design value and machining tolerance for each part of the component, which is evaluated by the machining evaluation device according to the first embodiment. In the machining system 1a, the component shape 41, which is the component shape after the machining program 42 has been executed, and the part information 40 for each part, which specifies the design value and machining tolerance, are entered into the machining tolerance setting unit 100. Thus, the machining tolerance setting unit 100 associates the part with the design value and the machining tolerance.

[0046] Here, a case is described in which component 7, as a machined object, is the plate gauge 80 with a width of 50 mm, a depth of 30 mm and a height of 10 mm, which was designed using three-dimensional CAD software. Fig. Figure 8 merely illustrates a representative value of the dimension of each part for ease of understanding.

[0047] The plate gauge 80 is a plate-shaped gauge with a rectangular top surface on an XY plane and features a multitude of holes arranged in a Z-axis direction. For example, a hole HA with a diameter of 20 mm is located in the center of the plate gauge 80. Furthermore, holes HB1 and HB2, and holes HC1 and HC2, are located at the four corners of the plate gauge 80. Within the plate gauge 80, a line connecting the center of hole HB1 and the center of hole HC1 runs parallel to a line connecting the center of hole HC2 and the center of hole HB2.

[0048] The diameter of hole HA has a design dimension of 20 mm, however, an error of ±0.01 mm is permissible during actual machining. In the machining tolerance setting unit 100, the design value of 20 mm and the machining tolerance, including an upper limit for dimensional accuracy of +0.01 mm and a lower limit for dimensional accuracy of -0.01 mm, are set for hole HA.

[0049] In addition, in the machining tolerance setting unit 100, for example a design value of 20 mm and the machining tolerance, including an upper limit for dimensional accuracy of +0.1 mm and a lower limit for dimensional accuracy of 0 mm, are set for the center distance between the hole HB1 and the hole HC1.

[0050] Furthermore, a surface accuracy of Ra 6.3 µm is set for the upper surface of the plate gauge 80 in the machining tolerance setting unit 100. It should be noted that only the upper limit is set for the surface accuracy tolerance; the lower limit is not set. In addition, the design value for the surface accuracy does not need to be set.

[0051] As described above, component 7 generally contains, in many cases, a part requiring strict machining accuracy to fulfill its intended function, such as a connecting part for joining another component, and a part without a specific function and therefore without strict machining accuracy. Furthermore, a part with a function requires a wide range of machining accuracy, depending on the required function. The design value can be set graphically by the system user on a screen displaying a three-dimensional CAD model, or it can be automatically read from the CAD model by the machining tolerance setting unit 100. The machining tolerance is set, for example, by the system user entering a keystroke.Furthermore, the machining tolerance setting unit 100 can automatically set a predetermined standard machining tolerance for machining tolerances that are not explicitly entered by the system user.

[0052] Fig. Figure 9 is a block diagram illustrating an example configuration of the machining simulation execution unit included in the machining evaluation device according to the first embodiment. The machining simulation execution unit 101a includes a command value calculation simulation unit 14, servo control simulation units 5X, 5Y and 5Z, a process control simulation unit 15, drive mechanism model units 16X, 16Y and 16Z, a model unit 17 for a mechanical structure, a process model unit 18 and a prediction unit 19 for a machined shape.

[0053] The command value calculation simulation unit 14 is connected to the servo control simulation units 5X to 5Z and the process control simulation unit 15. The servo control simulation unit 5X is connected to the drive mechanism model unit 16X, the servo control simulation unit 5Y is connected to the drive mechanism model unit 16Y, and the servo control simulation unit 5Z is connected to the drive mechanism model unit 16Z. The model unit 17 for a mechanical structure is connected to the drive mechanism model units 16X to 16Z and the process model unit 18. The process model unit 18 is connected to the process control simulation unit 15 and the prediction unit 19 for a machined mold.

[0054] In the machining simulation execution unit 101a, the machining program 42 is entered into the command value calculation simulation unit 14. Furthermore, the machine model information 45 is entered into the command value calculation simulation unit 14, the servo control simulation units 5X to 5Z, the process control simulation unit 15, the drive mechanism model units 16X to 16Z, the model unit 17 for mechanical structures, and the process model unit 18. It should be noted that in Fig. 9. The illustration of a connecting line between the machine model information 45 and the command value calculation simulation unit 14, and a connecting line between the machine model information 45 and each of the servo control simulation units 5X to 5Z, has been omitted. Furthermore, in Fig. 9 The illustration of a connecting line between the machine model information 45 and the process control simulation unit 15 and a connecting line between the machine model information 45 and each of the drive mechanism model units 16X to 16Z has been omitted.

[0055] The command value calculation simulation unit 14, the servo control simulation units 5X to 5Z, the process control simulation unit 15, the drive mechanism model units 16X to 16Z, the model unit 17 for a mechanical structure and the process model unit 18 are models that simulate the properties of the machine tool 99 with numerical control and are set on the basis of models described in the machine model information 45.

[0056] The command value calculation simulation unit 14 is a model that, based on the machining program 42, calculates predicted axis commands 6X to 6Z and a predicted process command 55 using a command path of the machine tool 99 with numerical control. The predicted axis command 6X is a predicted axis command for the X-axis, the predicted axis command 6Y is a predicted axis command for the Y-axis, and the predicted axis command 6Z is a predicted axis command for the Z-axis. The predicted axis commands 6X to 6Z are, for example, predicted position commands (the position command Xc in the case of the X-axis).

[0057] Predicted process command 55 is a predicted command for spindle 83. Predicted process command 55 is, for example, a predicted spindle speed command. The command value calculation simulation unit 14 sends the predicted axis commands 6X to 6Z to the servo control simulation units 5X to 5Z and sends predicted process command 55 to the process control simulation unit 15.

[0058] The servo control simulation units 5X to 5Z are models that simulate the servo control unit 6a. Based on the machine model information 45, the servo control simulation units 5X to 5Z, for example, set up models and model parameters that numerically simulate the control logic of a servo amplifier contained in the machine tool 99 with numerical control. The servo control simulation units 5X to 5Z simulate the servo control unit 6a of the machine tool 99 with numerical control based on the corresponding predicted axis commands 6X to 6Z for the X-axis up to the Z-axis and corresponding predicted axis feedbacks 32X to 32Z from the drive mechanism model units 16X to 16Z. The predicted axis feedbacks 32X to 32Z are information that specify the predicted positions of the X-axis up to the Z-axis.

[0059] The servo control simulation units 5X to 5Z simulate the servo control unit 6a to calculate predicted actuator commands 31X to 31Z for the X-axis up to the Z-axis, each from the predicted axis commands 6X to 6Z for the X-axis up to the Z-axis. The predicted actuator commands 31X to 31Z are actuator commands that are predicted for each of the X-axis up to the Z-axis. The servo control simulation units 5X to 5Z send the predicted actuator commands 31X to 31Z to the drive mechanism model units 16X to 16Z.

[0060] The process control simulation unit 15 is a model that simulates the process control 5 of the machine tool 99 with numerical control based on the predicted process command 55. For example, the process control simulation unit 15 provides a model and a model parameter that numerically simulate the control logic of a spindle amplifier contained in the machine tool 99 with numerical control, based on the machine model information 45.

[0061] The process control simulation unit 15 simulates the process control 5 to calculate a predicted spindle current 56 from the predicted process command 55. This predicted spindle current represents a predicted value of the process variable. The process control simulation unit 15 sends the predicted spindle current 56 to the process model unit 18.

[0062] The drive mechanism model units 16X to 16Z calculate corresponding predicted axis positions 33X to 33Z from the respective predicted actuator commands 31X to 31Z and respective predicted axis disturbances 34X to 34Z, which are sent by model unit 17 for a mechanical structure. The predicted axis disturbances 34X to 34Z are disturbances received on the X-axis up to the Z-axis. The predicted axis positions 33X to 33Z are predicted positions for the X-axis up to the Z-axis. That is, the predicted axis position 33X is the predicted position in the X-axis direction on the X-axis, the predicted axis position 33Y is the predicted position in the Y-axis direction on the Y-axis, and the predicted axis position 33Z is the predicted position in the Z-axis direction on the Z-axis.

[0063] The drive mechanism model units 16X to 16Z, for example, use a dynamic model in which four inertias—motor inertia, clutch inertia, ball screw inertia, and table mass—are linked by a spring and damping mechanism. This dynamic model is a four-inertia model and is a high-accuracy model of the drive mechanisms 97X to 97Z. The four-inertia model receives motor torque and predicted disturbance as inputs, uses a motor position as feedback information for a predicted axis, and outputs a table position as the predicted axis positions 33X to 33Z. The drive mechanism model units 16X to 16Z can also include a friction model that describes a frictional force on the table using an equation with rotational speed as input.

[0064] The drive mechanism model units 16X to 16Z send the respective predicted axis positions 33X to 33Z to model unit 17 for a mechanical structure. The drive mechanism model units 16X to 16Z also send the respective predicted axis positions 33X to 33Z as the predicted axis feedback 32X to 32Z to the servo control simulation units 5X to 5Z.

[0065] The model unit 17 for a mechanical structure is a model that receives the predicted axis positions 33X to 33Z for the X-axis up to the Z-axis and a predicted process disturbance 36, which are sent as inputs by the process model unit 18, and outputs the predicted axis disturbances 34X to 34Z of the X-axis up to the Z-axis and a tool base position 35, which is an example of a work point displacement. The predicted process disturbance 36 is a disturbance received by the spindle 83. The tool base position 35 is information indicating the position of the base of the tool 76.

[0066] For example, based on the machine model information 45 for the numerically controlled machine tool 99, the model unit 17 for a mechanical structure selects a state-space model with three inputs and four outputs that corresponds to the mechanical structure 98 in a C-column configuration, where the spindle 83 and the worktable 77 are arranged in a C-shape. The model unit 17 for a mechanical structure calculates the tool base position 35 based on the selected state-space model. The model unit 17 for a mechanical structure sends the calculated tool base position 35 to the process model unit 18.

[0067] The process model unit 18 receives the tool base position 35, i.e., the work point displacement, and the predicted spindle current 56, i.e., a predicted process variable, as inputs and outputs the predicted process disturbance 36 and a tool tip position 37, i.e., a predicted work result. The tool tip position 37 is information indicating the position of one tip of the tool 76.

[0068] In a case where the CNC machine tool 99 performs milling using a face mill, the process model unit 18 predicts a machining force due to milling, outputs a cutting force as the predicted process disturbance 36 in each axial direction, and calculates the tool tip position 37 during machining. The process model unit 18 sends the calculated tool tip position 37 to the prediction unit 19 for a machined shape.

[0069] The prediction unit 19 for a machined shape uses the tool information 43, the workpiece information 44 and the tool tip position 37 to geometrically calculate a material to be removed from the surface of the workpiece 78 by the tool 76 and to calculate a shape of a machined surface formed by machining.

[0070] The machine model information 45 is information regarding input / output data, the number of parameters, a model structure, and similar model characteristics. The various models mentioned above, which are set in the machining simulation execution unit 101a by the machine model information 45, are examples. The machine model information 45 enables the machining simulation execution unit 101a to set a model with any model structure, as long as a calculation formula defining an input / output relationship is required for each model.That is, the model structure of the model, which is stored in the machine model information 45, can, for example, be a model structure that is described by any of the various modeling methods of known black-box, white-box, gray-box, proxy, behavioral, state-space, subspace, transfer function and finite element methods (FEM).

[0071] Each model set in the machining simulation execution unit 101a can be registered in the machine model information 45 by any method. For example, when the CNC machine tool 99 is shipped, each configured model can be pre-registered by a manufacturer of the mechanical fixture unit 96 included in the CNC machine tool 99, or by a manufacturer of the CNC itself. Furthermore, the machining system 1a can, for example, download and use a model created by the manufacturer of the mechanical fixture unit 96, the CNC manufacturer, a software vendor, a third party, or the like.Furthermore, the machining system 1a can use a model that is created and registered according to a machine owned by a user of the mechanical device unit 96.

[0072] Fig. Figure 10 is a representation to illustrate examples of the partial machining error output by the machining evaluation device according to the first embodiment. Fig. Figure 10 illustrates examples of the calculated result of the partial machining error 48S, which is output by the first machining result evaluation unit 102. The in Fig. 10 illustrated plate theory 80 corresponds to the one in Fig. 8. illustrated plate theory 80.

[0073] The partial machining error 48S, output by the first machining result evaluation unit 102, is displayed on a display device or the like. It should be noted that the machining evaluation unit 20a can display the machining tolerance together with the partial machining error 48S on the display device.

[0074] In the case of Fig. The hole HA formed in the center of the plate gauge 80 has a diameter of 20.001 mm, which is obtained through machining simulation. Therefore, if the design value of the diameter is 20 mm, the partial machining error 48S is 0.001 mm. Since hole HA has a machining tolerance of +0.01 mm as the upper limit for dimensional accuracy and -0.01 mm as the lower limit, hole HA's dimensions are within tolerance.

[0075] Furthermore, the center-to-center distance between hole HB1 and hole HC1 has a dimension of 20.2 mm, which is obtained through machining simulation. Therefore, if the design value is 20 mm, the partial machining error 48S is 0.2 mm. Since the center-to-center distance between hole HB1 and hole HC1 has a machining tolerance of +0.1 mm as the upper limit for dimensional accuracy and 0 mm as the lower limit for dimensional accuracy, the center-to-center distance between hole HB1 and hole HC1 is not within the tolerance.

[0076] Furthermore, the surface accuracy of the upper surface of the plate gauge 80 has a value of Ra 4 µm, which is obtained through machining simulation. Therefore, if the design value (lower limit) of the surface accuracy is Ra 6.3 µm, the partial machining error 48S is Ra 2.3 µm. The surface accuracy of the upper surface of the plate gauge 80 is within tolerance, as the value of the partial machining error 48S is 0 or greater.

[0077] The first machining result evaluation unit 102 can output the calculated result of the partial machining error 48S for each part graphically, in a tabular format as tabular data, or in a table by displaying the calculated result next to the machining tolerance.

[0078] As described above, if the machining accuracy of component 7 is predicted in advance by simulation or the like for workpiece 78, the required accuracy (the machining tolerance) is different for each part (for each functional part) of component 7, so it is desirable to determine whether the required machining tolerance is met for each part or not.

[0079] The machining system 1a, which includes the machining evaluation device 20a according to the first embodiment, can calculate the machining error predicted by simulation for each part requiring accuracy. Consequently, the machining system 1a can graphically display the part machining error 48S with respect to the design value, i.e., the predicted value of the machining error with respect to the design value.

[0080] Consequently, the system user can easily determine the quality of the machining result, which is predicted by simulation based on the part machining error 48S for each part. The system user can also easily correct the machining program 42, the tool information 43, and the like, so that no part fails to meet the required accuracy (the machining tolerance). Furthermore, since the machining system 1a determines whether the machining error is within the required machining tolerance for each part, the system user can set the machining tolerance for the machining error to high for the part that does not require accuracy. Consequently, the machining system 1a can perform machining under conditions where this is necessary and sufficient accuracy is predicted.

[0081] This document describes hardware for implementing the machining evaluation device 20a according to the first embodiment. The machining tolerance setting unit 100, the machining simulation execution unit 101a, and the first machining result evaluation unit 102 of the machining evaluation device 20a are implemented by a processing circuit. The processing circuit can include a memory and a processor that executes a program stored in the memory, or it can include dedicated hardware.

[0082] Fig. Figure 11 is a diagram illustrating an example of a case in which the processing circuit implementing the machining evaluation device of the machining system according to the first embodiment includes the processor and the memory. In a case where the processing circuit includes a processor 201 and a memory 202, the machining tolerance setting unit 100, the machining simulation execution unit 101a, and the first machining result evaluation unit 102 are implemented by software, firmware, or a combination of software and firmware. The software or firmware is described as programs and stored in the memory 202. The processing circuit implements the functions by having the processor 201 read and execute the programs stored in the memory 202.This means that the processing circuit contains the memory 202 for storing the programs that lead to the execution of the processing of the machining evaluation device 20a. It can also be said that these programs cause a computer 23 to execute operations and procedures relating to the machining evaluation device 20a.

[0083] The processor 201 can be a central processing unit (CPU), a processing unit, an arithmetic logic unit (ALU), a microprocessor, a microcomputer, a digital signal processor (DSP), or the like. Furthermore, the memory 202 corresponds, for example, to non-volatile or volatile semiconductor memory, such as random-access memory (RAM), read-only memory (ROM), flash memory, erasable programmable ROM (EPROM), or electrical EPROM (EEPROM (registered trademark)), a magnetic disk, a flexible disk, an optical disk, a compact disc, a mini-disc, a digital versatile disc (DVD), or the like.

[0084] Fig. Figure 12 is a representation illustrating an example of a case in which a processing circuit implementing the processing evaluation device according to the first embodiment contains the hardware. In the case where the processing circuit contains the dedicated hardware, the representation in Fig. Figure 12 illustrates the processing circuit 203, for example, a single circuit, a complex circuit, a programmed processor, a parallel programmed processor, an application-specific integrated circuit (ASIC), a field-programmable gate array (FPGA), or a combination thereof. The functions of the processing evaluation device 20a can be implemented individually or jointly by the processing circuit 203.

[0085] It should be noted that the functions of the processing evaluation device 20a can be implemented partly by the dedicated hardware and partly by the software or firmware. The processing circuit can therefore implement the functions described above by the dedicated hardware, software, firmware, or a combination thereof.

[0086] This section describes a mechanical device applicable to machining system 1a. The mechanical device applicable to machining system 1a includes the machine tool 99 with numerical control, an industrial robot, and the like.

[0087] The machine tool 99 with numerical control, applicable to the machining system 1a, includes a cutting machine that drives a cutting tool or a workpiece with an axis to remove material from a surface of the workpiece, a laser machine that drives a laser light source with an axis to cut a workpiece, an electrical discharge machining machine that drives an electrode tool or a wire tool with an axis to generate electrical discharge between the electrode tool or the wire tool and a workpiece and to remove material, and the like.The machine tool 99 with numerical control, applicable to the machining system 1a, further includes a spark erosion machining machine which drives an electrode tool or a wire tool with an axis to generate electrical discharge between the electrode tool or the wire tool and a workpiece and to remove material, an additive manufacturing (AM) machine or a 3D printer which melts a wire or powdered material with a laser to carry out additive manufacturing, and the like.

[0088] The industrial robot applicable to the machining system 1a includes a robot that drives each joint with a servo control to perform machining, such as cutting, welding or additive manufacturing, using a rotary tool or laser light attached to a tip.

[0089] Various operating errors can occur in the mechanical device containing such a servo control for implementing feedback control. For example, response delay caused by mechanical properties of the device, motion error caused by friction on a sliding surface, disturbance forces such as cutting or contact forces generated by work performed on the device, overshoot caused by the control setting, and the like are known as transient errors that occur when the feedback control fails.Moreover, in the mechanical device that performs the machining, a workpiece or part that actually performs the machining, such as tool 76, is a control target that is actually to be controlled. However, it is difficult to mount a position detector in precise alignment with the control target. For this reason, it is also known that even if the movement indicated in a detected result by the position detector is error-free, the movement of the actual control target exhibits an error, such as vibration or a reaction delay.

[0090] In the first embodiment, the machining system 1a calculates the simulation shape 47S of component 7 and calculates and outputs the partial machining defect 48S for each part of component 7. Consequently, the machining system 1a can provide the partial machining defect 48S to the system user before a machining defect occurs during actual machining and can prevent a machining defect.

[0091] As described above, in the first embodiment, the machining evaluation device 20a calculates the partial machining error 48S, which is the predicted value of the machining error, for each specified part based on the design value and the simulation shape 47S, which is predicted by the machining simulation as the component shape after the machining program 42 is executed. Consequently, the machining evaluation device 20a can provide the system user with the partial machining error 48S, which can evaluate the machining error of the predicted shape for each part of component 7, which has a different machining accuracy tolerance for each part. Therefore, the system user can evaluate the machining error of the predicted shape for each part of component 7, which has a different machining accuracy tolerance for each part. Second embodiment.

[0092] Next, a second embodiment will be described with reference to the Fig. Described in Figures 13 to 15. In the second embodiment, a machining evaluation device determines whether a machining defect for each part, obtained through simulation, meets a tolerance or not. The second embodiment mainly describes differences from the first embodiment.

[0093] Fig. Figure 13 is a block diagram illustrating an example configuration of the machining evaluation device included in a machining system according to the second embodiment. Components in Fig. 13, which achieve the same functions as those of the machining evaluation device 20a, which is in the machining system 1a of the in Fig. The reference numerals used in the first embodiment illustrated in section 6 are the same as those in [reference numeral 6]. Fig. 6 is assigned, and a redundant description is omitted. In Fig. Figure 13 omits the illustration of the computer 23, the network hub 24 and the machine tool 99 with numerical control, which are included in a machining system 1b of the second embodiment.

[0094] The machining system 1b of the second embodiment differs from the machining system 1a in that it includes a machining evaluation device 20b instead of the machining evaluation device 20a. The machining system 1b also includes a machining execution unit 104b.

[0095] Machining evaluation device 20b differs from machining evaluation device 20a in that it contains a machining simulation execution unit 101b instead of the machining simulation execution unit 101a. Details of the machining simulation execution unit 101b are described below.

[0096] The machining evaluation device 20b also includes a first result determination unit 103b. The first result determination unit 103b is connected to the machining tolerance setting unit 100, the first machining result evaluation unit 102 and the machining execution unit 104b.

[0097] In the second embodiment, the machining evaluation device 20b is implemented in the computer 23, and the machining execution unit 104b is implemented in the machine tool 99 with numerical control. Furthermore, in the second embodiment, a two-dimensional CAD drawing 39 is input into the machining tolerance setting unit 100. That is, the machining tolerance setting unit 100 of the second embodiment receives the two-dimensional CAD drawing 39 instead of the component shape 41. In addition, the machining tolerance setting unit 100 of the second embodiment sends the part setting information 46 to the first machining result evaluation unit 102 and the first result determination unit 103b. Moreover, the first machining result evaluation unit 102 of the second embodiment sends the part machining error 48S for each part to the first result determination unit 103b.

[0098] It should be noted that the first result determination unit 103b can receive the part setting information 46 from the first machining result evaluation unit 102. Based on the part machining defect 48S and the machining tolerance contained in the part setting information 46, the first result determination unit 103b determines whether the machining defect is acceptable or unacceptable for each part. That is, the first result determination unit 103b compares the part machining defect 48S for each part with the machining tolerance for each part contained in the part setting information 46 and outputs a part determination result 50S, which indicates a simulation-based determination result for the machining defect for each part, to an external device. An example of an external device is a display device. In this case, the part determination result 50S is displayed by the display device.

[0099] The first result determination unit 103b determines for all specified parts whether the machining errors obtained through simulation are within the machining tolerance or not. That is, the first result determination unit 103b determines whether all of the partial machining errors 48S are acceptable for the parts or not.

[0100] In a case where the machining errors, as determined by simulation, are within the machining tolerance for all parts—that is, in a case where all of the partial machining errors 48S are acceptable for the parts—the first result determination unit 103b issues a machining execution command 49 to the machining execution unit 104b. Machining execution command 49 is an instruction to execute a machining operation. Consequently, machining execution unit 104b performs a machining operation to produce component 7, i.e., a machined component. That is, when machining execution command 49 is received, machining execution unit 104b executes the machining program 42 on the numerically controlled machine tool 99 and performs the machining operation on workpiece 78. When machining execution unit 104b completes the machining operation, component 7 is finished.

[0101] Fig. Figure 14 is a representation illustrating an example of the two-dimensional CAD drawing that is entered into the machining evaluation device according to the second embodiment. The two-dimensional CAD drawing 39 is entered into the machining tolerance setting unit 100 of the machining evaluation device 20b. However, it should be noted that Fig. Figure 14 illustrates only representative construction values ​​to simplify the description. Furthermore, a three-sided view is normally required to define a three-dimensional shape; however, only a front view is shown here for the sake of simplicity.

[0102] The two-dimensional CAD drawing 39 contains design values, machining tolerances, and the like. It also illustrates machining tolerances such as perpendicularity, parallelism, and the like. Therefore, when the system user enters the design values, machining tolerances, and the like into the external system based on the two-dimensional CAD drawing 39, the necessary information can be extracted from the drawing and automatically listed without keyboard input.

[0103] Furthermore, the machining tolerance setting unit 100 of the machining evaluation device 20b can receive not only the two-dimensional CAD drawing 39, but also three-dimensional CAD data in which the machining tolerances are set. Moreover, the notation in the example from Fig. 14 of the dimension and cross notation for a mechanical drawing defined in Japanese Industrial Standards (JIS), but as long as the design value of the machining and at least one of the upper limit or the lower limit of the machining tolerance can be defined, the component shape 41 in two dimensions, which are entered into the machining tolerance setting unit 100, can be mapped by any mapping method.

[0104] Fig. Figure 15 is a block diagram illustrating an example configuration of the machining simulation execution unit included in the machining evaluation device according to the second embodiment. Components in Fig. 15, which achieve the same functions as those of the machining evaluation device 101a, which are in the machining system 20a of the in Fig. The reference numerals used in the first embodiment illustrated in 9 are the same as those in Fig. 9 is assigned, and a redundant description is omitted.

[0105] The machining simulation execution unit 101b differs from the machining simulation execution unit 101a in that it does not contain the process model unit 18 and the process control simulation unit 15.

[0106] The machining simulation execution unit 101b of the machining evaluation device 20b assumes that the influence of a process model is sufficiently small for machining operations involving small steps, such as finishing and laser processing, to achieve a highly accurate machining simulation, even when the machined shape is predicted using the base position of the tool 76. Furthermore, the machining simulation execution unit 101b can simplify the simulation and reduce computation time by omitting the process model. Therefore, the machining simulation execution unit 101b of the second embodiment calculates the simulation shape 47S without using the process model unit 18 and the process control simulation unit 15.

[0107] It should be noted that the machining evaluation device 20b can receive the component shape 41 as input instead of the two-dimensional CAD drawing 39. Furthermore, the machining evaluation device 20b can contain the machining simulation execution unit 101a instead of the machining simulation execution unit 101b.

[0108] As described above, the machining system 1b of the second embodiment compares the machining error for each part, obtained through simulation, with the preset machining tolerance for each part, thereby determining whether the machining error generated by the simulation is within the machining tolerance. Then, if the machining errors for all parts are acceptable, the machining system 1b instructs the machining execution unit 104b to machine the workpiece 78. Consequently, the machining system 1b can produce component 7 within the design machining tolerance without requiring the system user to input a large amount of information. Third embodiment.

[0109] Next, a third embodiment will be described with reference to Fig. 16. In the third embodiment, if a part is present whose machining defect, as determined by simulation, is not within a machining tolerance, a machining evaluation device modifies a machining condition such that the machining defects are acceptable for all parts. The third embodiment mainly describes differences from the first and second embodiments.

[0110] Fig. Figure 16 is a block diagram illustrating an example configuration of the machining evaluation device included in a machining system according to the third embodiment. Components in Fig. 16, which have the same functions as those of the in Fig. The same reference numerals are used as those in 13 illustrated in machining system 1b of the second embodiment. Fig. 13 is assigned, and a redundant description is omitted. In Fig. Figure 16 omits the illustration of the computer 23, the network hub 24 and the numerically controlled machine tool 99, which are included in a machining system 1c of the third embodiment.

[0111] The machining system 1c of the third embodiment differs from the machining system 1b in that it includes a machining evaluation device 20c instead of the machining evaluation device 20b. The machining evaluation device 20c includes a machining condition optimization execution unit 111 in addition to the components contained in the machining evaluation device 20b. The machining condition optimization execution unit 111 is connected to the machining simulation execution unit 101b and the first result determination unit 103b.

[0112] It should be noted that the machining evaluation device 20c can contain the machining simulation execution unit 101a instead of the machining simulation execution unit 101b. Furthermore, the machining tolerance setting unit 100 can receive either the two-dimensional CAD drawing 39 or the component shape 41 as input. Fig. Figure 16 illustrates a case in which the machining tolerance setting unit 100 receives the two-dimensional CAD drawing 39 as input.

[0113] The machining simulation execution unit 101b of the third embodiment sends the simulation form 47S to the first machining result evaluation unit 102 and the machining condition optimization execution unit 111. In addition, the first result determination unit 103b of the third embodiment sends the part determination result 50S for each part to an external device and the machining condition optimization execution unit 111.

[0114] After receiving the simulation form 47S and a list of part determination results 50S for the parts, the machining condition optimization execution unit 111 determines whether the list of part determination results 50S contains the part determination result 50S that indicates a part that does not meet the machining tolerance. Upon receiving the part determination result 50S that indicates the part that does not meet the machining tolerance from the first result determination unit 103b, the machining condition optimization execution unit 111 corrects at least one of the machine model information 45 or the machining program 42.

[0115] In a case where a part is identified as unacceptable by the first result determination unit 103b, i.e., in a case where the list of part determination results 50S contains the part that does not meet the machining tolerance, the machining condition optimization execution unit 111 corrects at least one of the machine model information 45 or the machining program 42 until the part that does not meet the machining tolerance is no longer included. The machining system 1c then repeats the machining simulation using the machine model information 45 and the machining program 42, at least one of which has been corrected, recalculates the part machining error 48S, and redetermines the machining error for each part. Then, if not all of the parts meet the machining tolerance, the machining is not performed.Thus, the machining system 1c repeats the correction of at least one of the machine model information 45 or the machining program 42 until the list of part determination results 50S no longer contains the part that does not meet the machining tolerance.

[0116] Furthermore, the objective to be optimized by the machining condition optimization execution unit 111 includes, for example, the machining speed and spindle speed specified in the machining program 42, or the position of a command point specified by the machining program 42, and control parameters of the numerically controlled machine tool 99 contained in the machine model information 45. The control parameters of the numerically controlled machine tool 99 that are optimized by the machining condition optimization execution unit 111 are, for example, control parameters set in the machine model information 45 that influence the machining accuracy of the mechanical fixture unit 96.For example, in a case where the machining speed is too high and the accuracy of a corner section is not within the target accuracy due to the influence of a delay in the axis control, the machining condition optimization execution unit 111 corrects at least one of the machine model information 45 or the machining program 42 and sets the machining speed low, thereby making the machining tolerance achievable.

[0117] The control parameters of the machine tool 99 with numerical control include, for example, a servo gain, a slope error correction parameter, a perpendicularity error correction parameter, a vibration correction parameter, a friction correction parameter, an acceleration / braking parameter that defines an axis acceleration, and a parameter relating to a braking speed at the time of passing through the corner section.

[0118] An algorithm for machining condition optimization by the machining condition optimization execution unit 111 can be a preset sequence or a known optimization calculation algorithm. The machining condition optimization algorithm by the machining condition optimization execution unit 111 can also be an algorithm in which artificial intelligence (AI) learns the relationship between the control parameters and the partial machining error 48S in advance, and the machining condition optimization execution unit 111 modifies a control variable based on the learning result obtained by the AI.

[0119] An example of changing a control variable according to the preset sequence is changing the spindle speed to reduce or eliminate chatter vibration. Chatter vibration occurs when a vibration characteristic of a system in which the tool 76, the workpiece 78, and the mechanical structure 98 are connected manifests itself through a machining force generated by machining. When chatter vibration occurs, it is known that the vibration can be reduced by changing the spindle speed. For example, in a case where a decrease in machining accuracy caused by chatter vibration is detected in the simulation form 47S, the machining condition optimization execution unit 111 can avoid the chatter vibration by changing the spindle speed with an override rate preset by the optimization calculation algorithm.

[0120] Furthermore, the optimization of the control parameters using the known optimization calculation algorithm includes, for example, a parameter determination procedure that minimizes an evaluation function by fitting using a least squares algorithm, a parameter search using a genetic algorithm, a particle swarm optimization (PSO) procedure, a steepest descent procedure, or the like.

[0121] Learning using AI includes, for example, learning using a neural network, Q-learning, or similar methods to understand the relationship between control parameters and machining error. In this case, the machining condition optimization execution unit 111 searches for a combination of parameters that minimizes the machining error, based on the learned relationship between the control parameters and the machining error.

[0122] As with changing the machining program 42, the machining condition optimization execution unit 111, for example, in a case where a part is present that does not meet the dimensional accuracy, changes the command position by the machining program 42 in such a way that the dimensional accuracy is met.

[0123] The optimization algorithms described above are examples, and any calculation formula and algorithm can be used as long as the condition relating to the machining is repeatedly changed until the partial determination result 50S meets the set machining tolerance.

[0124] As described above, according to the third embodiment, even in the case where the machining error predicted by the simulation does not meet the machining tolerance, the machining system 1c automatically searches for the condition which meets the machining tolerance and performs the machining so that production does not stop. Fourth embodiment.

[0125] Next, a fourth embodiment will be described with reference to Fig. 17. In the fourth embodiment, a machined shape of component 7 is estimated based on the result of a measurement of the axis movement obtained from the numerically controlled machine tool 99, which forms component 7. Then, based on the estimated machined shape, a machining error is estimated, and it is determined for each part whether the estimated machining error meets the tolerance or not. Furthermore, a determination of whether the estimated machining error is acceptable or unacceptable for each part, and the part determination result 50S, which is a determination of whether the machining error obtained by simulation is acceptable or unacceptable for each part, are displayed. The fourth embodiment mainly describes differences from the second embodiment.

[0126] Fig. Figure 17 is a block diagram illustrating an example configuration of a machining evaluation device included in a machining system according to the fourth embodiment. Components in Fig. 17, which have the same functions as those of the in Fig. The same reference numerals are used as those in 13 illustrated in machining system 1b of the second embodiment. Fig. 13 is assigned, and a redundant description is omitted. In Fig. Figure 17 omits the illustration of the computer 23, the network hub 24 and the machine tool 99 with numerical control, which are included in a machining system 1d of the fourth embodiment.

[0127] The machining system 1d of the fourth embodiment differs from the machining system 1b in that it includes a machining evaluation device 20d instead of the machining evaluation device 20b. Furthermore, the machining system 1d differs from the machining system 1b in that it includes a machining execution unit 104d instead of the machining execution unit 104b.

[0128] The machining evaluation device 20d contains, in addition to the components contained in the machining evaluation device 20b, an estimation unit 105 for a machined shape, a second machining result evaluation unit 106 and a second result determination unit 107.

[0129] The estimation unit 105 for a machined shape is connected to the machining execution unit 104d and the second machining result evaluation unit 106. The second machining result evaluation unit 106 is connected to the second result determination unit 107. Furthermore, the second machining result evaluation unit 106 and the second result determination unit 107 are connected to the machining tolerance setting unit 100.

[0130] It should be noted that the machining evaluation device 20d can contain the machining simulation execution unit 101a instead of the machining simulation execution unit 101b. Furthermore, the machining tolerance setting unit 100 can receive either the two-dimensional CAD drawing 39 or the component shape 41 as input. Fig. Figure 17 illustrates a case in which the machining tolerance setting unit 100 receives the component shape 41 as the input.

[0131] The machining tolerance setting unit 100 of the fourth embodiment sends the part setting information 46 to the first machining result evaluation unit 102, the first result determination unit 103b, the second machining result evaluation unit 106 and the second result determination unit 107.

[0132] The machining execution unit 104d performs a machining operation to produce component 7 as a machined component and also queries data from the numerically controlled machine tool 99 during the machining process. The machining execution unit 104d can query the data using the numerical control contained in the numerically controlled machine tool 99 or it can query the data using a measuring device attached to the numerically controlled machine tool 99. The queried data is, for example, a position detector signal for each axis. That is, the queried data is data that represents the result of a measurement of the axis movement of the mechanical fixture unit 96 during machining. The machining execution unit 104d sends the queried data as machining data 51 to the estimating unit 105 for a machined shape.

[0133] The machining shape estimation unit 105 receives the machining data 51 and extracts the query data from it. Machining shape estimation unit 105 predicts the shape of component 7 through processing similar to that used by machining simulation execution unit 101b's machining shape prediction unit 19. Specifically, machining shape estimation unit 105 calculates the tool position 76 from a queryed position sensing signal indicating the position of each axis and calculates an estimated machining shape 52E, which represents a predicted (estimated) shape of component 7 based on the query data. The estimated machining shape 52E is the estimated shape of component 7 formed by machining. Machining shape estimation unit 105 sends the estimated machining shape 52E to the second machining result evaluation unit 106.

[0134] The second machining result evaluation unit 106 receives the part setting information 46 from the machining tolerance setting unit 100 and receives the estimated machined shape 52E from the estimation unit 105 for a machined shape. It should be noted that the second machining result evaluation unit 106 can receive the part setting information 46 from the first result determination unit 103b or the first machining result evaluation unit 102.

[0135] The second machining result evaluation unit 106 calculates the machining error by a similar processing procedure to the first machining result evaluation unit 102. In particular, the second machining result evaluation unit 106 uses the estimated machined shape 52E for each part and a design value for each part, which is stored in the part setting information 46 set by the machining tolerance setting unit 100, to calculate an estimated machining error 53E for each part, which represents the machining error in the estimated machined shape 52E.Thus, the first machining result evaluation unit 102 uses the simulation form 47S to calculate the part machining error 48S based on the simulation for each part, and the second machining result evaluation unit 106 uses the estimated machined form 52E to calculate the estimated machining error 53E based on the actual machining for each part. The second machining result evaluation unit 106 sends the estimated machining error 53E to the second result determination unit 107.

[0136] The second result determination unit 107 receives the part setting information 46 from the machining tolerance setting unit 100 and receives the estimated machining error 53E from the second machining result evaluation unit 106. It should be noted that the second result determination unit 107 can receive the part setting information 46 from the second machining result evaluation unit 106, the first result determination unit 103b, or the first machining result evaluation unit 102.

[0137] The second result determination unit 107 determines whether the machining defect is acceptable or unacceptable through processing similar to that performed by the first result determination unit 103b. Specifically, the second result determination unit 107 uses the estimated machining defect 53E for each part and the machining tolerance for each part, stored in the part setting information 46 and set by the machining tolerance setting unit 100, to determine whether the estimated machining defect 53E is acceptable or unacceptable. That is, the second result determination unit 107 determines whether the estimated machining defect 53E for each part meets the machining tolerance for each part.Thus, the first result determination unit 103b uses the part machining error 48S calculated from the simulation shape 47S to determine whether the simulation shape 47S is acceptable or unacceptable for each part, and the second result determination unit 107 uses the estimated machining error 53E calculated from the estimated machined shape 52E to determine whether the estimated machined shape 52E is acceptable or unacceptable for each part.

[0138] The second result determination unit 107 outputs an estimated determination result 54E for each part, indicating whether the estimated machined shape 52E (the estimated machining defect 53E) for each part is acceptable or unacceptable, to an external device. Furthermore, the first result determination unit 103b outputs the part determination result 50S for each part, indicating whether the simulated shape 47S (the part machining defect 48S) for each part is acceptable or unacceptable, to the external device. The external device in this case is, for example, a display device. The display device shows the estimated determination result 54E for each part and the part determination result 50S for each part.

[0139] Consequently, the system user can compare the part determination result 50S obtained through simulation for each part with the estimated determination result 54E obtained during processing for each part. In the display unit, for example, the part determination result 50S and the estimated determination result 54E can be shown as tabular data for each part, superimposed as a single figure on one screen, or displayed separately as two figures.

[0140] The system user instructs the numerically controlled machine tool 99 to perform machining in a case where all parts obtained through simulation are within the machining tolerance. In this case, if the machine model information 45 is unsuitable, a part obtained through actual machining may not be within the machining tolerance. In the fourth embodiment, the machining system 1d calculates the estimated machining error 53E from the measurement result of the axis movement during machining and outputs the estimated determination result 54E, which indicates whether the estimated machining error 53E is within the machining tolerance, so that the system user can easily determine whether the machine model information 45 is suitable or not.

[0141] As described above, the machining system 1d of the fourth embodiment determines whether the estimated machining error 53E, actually produced by the machining process, meets the machining tolerance or not, and outputs the estimated determination result 54E, which indicates the result of the determination. Furthermore, the machining system 1d determines whether the partial machining error 48S, calculated by the simulation, meets the machining tolerance or not, and outputs the partial determination result 50S, which indicates the result of the determination. Consequently, the system user can easily compare the estimated determination result 54E with the partial determination result 50S displayed on the display device. Therefore, the system user can easily compare any difference between a machining result predicted by the simulation and a machining result predicted based on the data during machining. Fifth embodiment.

[0142] Next, a fifth embodiment will be described with reference to Fig. 18 described. In the fifth embodiment, in a case where a difference between the part determination result 50S for each part and the estimated determination result 54E for each part is a specific value or more, a machining evaluation device corrects a machine model in the machine model information 45. The fifth embodiment mainly describes differences from the fourth embodiment.

[0143] Fig. Figure 18 is a block diagram illustrating an example of a configuration of the machining evaluation device included in a machining system according to the fifth embodiment. Components in Fig. 18, which have the same functions as those of the in Fig. The same reference numerals are used as those in 17 illustrated in machining system 1d of the fourth embodiment. Fig. 17 is assigned, and a redundant description is omitted. In Fig. Figure 18 omits the illustration of the computer 23, the network hub 24 and the numerically controlled machine tool 99 that are included in a machining system 1e of the fifth embodiment.

[0144] The machining system 1e of the fifth embodiment differs from the machining system 1d in that it includes a machining evaluation device 20e instead of the machining evaluation device 20d.

[0145] The machining evaluation device 20e contains a model update determination unit 108, a model update execution unit 109, and a machine model database (DB) 110, in addition to the components contained in the machining evaluation device 20d. The model update determination unit 108 is connected to the first result determination unit 103b and the second result determination unit 107. The model update execution unit 109 is connected to the model update determination unit 108, the machining execution unit 104d, the machine model DB 110, and the machining simulation execution unit 101b. The machine model DB 110 is connected to the machining simulation execution unit 101b.

[0146] It should be noted that the machining evaluation device 20e can contain the machining simulation execution unit 101a instead of the machining simulation execution unit 101b. Furthermore, the machining tolerance setting unit 100 can receive either the two-dimensional CAD drawing 39 or the component shape 41 as input. Fig. Figure 18 illustrates a case in which the machining tolerance setting unit 100 receives the component shape 41 as the input.

[0147] The first result determination unit 103b of the processing evaluation device 20e sends the partial determination result 50S to the model update determination unit 108. In addition, the second result determination unit 107 of the processing evaluation device 20e sends the estimated determination result 54E to the model update determination unit 108.

[0148] Furthermore, the estimation unit 105 for a machined shape of the machining evaluation device 20e sends the estimated machined shape 52E to the second machining result evaluation unit 106 and the model update execution unit 109. In addition, the machining simulation execution unit 101b of the machining evaluation device 20e sends the simulation shape 47S to the first machining result evaluation unit 102 and the model update execution unit 109.

[0149] The model update determination unit 108 determines, based on a comparison between the part determination result 50S for each part and the estimated determination result 54E for each part, whether the machine model information 45 needs to be updated. If it is determined that the machine model information 45 needs to be updated, the model update determination unit 108 issues a model update command 84 to instruct the model update execution unit 109 to update the machine model information 45.

[0150] For example, in a case where the part determination result 50S for each part and the estimated determination result 54E for each part differ, the model update determination unit 108 determines that the accuracy of the machine model represented in the machine model information 45 is insufficient and issues the model update command 84. The model update determination unit 108 can issue the model update command 84 in a case where, for example, the number of parts for which the results do not match between the part determination result 50S for each part and the estimated determination result 54E for each part exceeds a preset threshold.

[0151] When the model update determination unit 108 determines that the machine model information 45 needs to be updated, the model update execution unit 109 receives the model update command 84 from the model update determination unit 108. Upon receiving the model update command 84, the model update execution unit 109 reads the latest machine model information 45 from the machine model database 110. The model update execution unit 109 then performs the update of the machine model information 45 using the simulation form 47S and the estimated machined form 52E. Specifically, the model update execution unit 109 updates the machine model information contained in the machine model information 45.

[0152] In the third embodiment, the machining condition optimization execution unit 111 changes the parameters such that the control parameters or the like achieve the target component determination result 50S, whereas in the fifth embodiment, the model update execution unit 109 updates the machine model, which maps the properties of the machine tool 99 with numerical control, parameters of the machine model and the like in the machine model information 45.

[0153] The model update execution unit 109 updates the machine model using an axis movement path stored during the machining simulation and an axis movement path recorded during machining. For example, the model update execution unit 109 updates the machine model in a case where there is an error in a design-related parameter, such as stiffness (including inertia), in the machine model, and the simulation shape 47S of a part does not match the estimated shape of the part to be machined. In this case, the model update execution unit 109 updates the machine model so that the simulation shape 47S matches the estimated machined shape 52E.

[0154] When updating the machine model, the model update execution unit 109 modifies the machine model parameters by comparing the data from the simulation form 47S, the estimated machined form 52E, and the original machine model information 45 (the most recent machine model information 45 read out). An algorithm executed by the model update execution unit 109 to modify model parameters can be a known system identification or modeling procedure, or it can be a procedure using AI learning. In the AI-based procedure, the AI ​​learns the relationship between the estimated machined form 52E and the simulation form 47S, and the model update execution unit 109 updates the machine model information 45 based on the learning outcome obtained by the AI.This means that the AI ​​learns the machine model information 45, which corresponds to the relationship between the estimated machined shape 52E and the simulation shape 47S. When updating the machine model, the model update execution unit 109 calculates the machine model information 45, which corresponds to the relationship between the estimated machined shape 52E and the simulation shape 47S, based on the learning outcome and updates the current machine model information 45 with the machine model information 45 obtained as the calculated result.

[0155] The model update execution unit 109 stores the updated machine model information 45 and a model update history 57, which indicates the update history of the machine model, in the machine model database 110. The machine model database 110 is a database that stores the updated machine model information 45 and the model update history 57 in relation to each other.

[0156] When the machine model information 45 in the machine model DB 110 is updated, the machining simulation execution unit 101b reads the updated machine model information 45 from the machine model DB 110 and re-executes the machining simulation.

[0157] As described above, in the machining system 1e of the fifth embodiment, if the accuracy of the machine model representing the machine characteristics contained in the machine model information 45 is insufficient, the machining evaluation device 20e updates the machine model in the machine model information 45. Consequently, the machining system 1e can compare the estimated machined shape 52E with the simulation shape 47S and simulate the machining error with higher accuracy. Sixth embodiment.

[0158] Next, a sixth embodiment will be described with reference to the Fig. 19 and Fig. 20. In the sixth embodiment, the actual shape of component 7, obtained after completion of machining, is measured. A machining error is then calculated based on the measured machined shape, and it is determined for each part whether the calculated machining error meets the tolerance or not. Furthermore, the determination of whether the machining error obtained by measurement is acceptable or unacceptable for each part, and the part determination result 50S, which is the determination of whether the machining error obtained by simulation is acceptable or unacceptable for each part, are displayed. The sixth embodiment mainly describes differences from the fourth embodiment.

[0159] Fig. Figure 19 is a block diagram illustrating an example configuration of a machining evaluation device included in a machining system according to the sixth embodiment. Components in Fig. 19, which have the same functions as those of the in Fig. The same reference numerals are used as those in 17 illustrated in machining system 1d of the fourth embodiment. Fig. 17 is assigned, and a redundant description is omitted. In Fig. Figure 19 omits the illustration of the computer 23, the network hub 24 and the machine tool 99 with numerical control, which are included in a machining system 1f of the sixth embodiment.

[0160] The machining system 1f of the sixth embodiment differs from the machining system 1d in that it includes a machining evaluation device 20f instead of the machining evaluation device 20d. Furthermore, the machining system 1f differs from the machining system 1d in that it includes a machining execution unit 104f instead of the machining execution unit 104d. The machining system 1f also includes a measuring unit 115 for a machined shape. In addition, the machining evaluation device 20f differs from the machining evaluation device 20d in that it does not include the estimation unit 105 for a machined shape, but the other components are identical between the machining evaluation devices 20f and 20d. The measuring unit 115 for a machined shape is connected to the second machining result determination unit 106.The component 7 produced by the machining execution unit 104f is conveyed to the measuring unit 115 for a machined mold.

[0161] It should be noted that the machining evaluation device 20f can contain the machining simulation execution unit 101a instead of the machining simulation execution unit 101b. Furthermore, the machining tolerance setting unit 100 can receive either the two-dimensional CAD drawing 39 or the component shape 41 as input. Fig. Figure 19 illustrates a case in which the machining tolerance setting unit 100 receives the component shape 41 as the input.

[0162] The machining system 1f according to the sixth embodiment includes the machining unit 115 instead of the machining unit 105. The machining unit 115 uses the component 7 formed by the machining execution unit 104f (the component 7 obtained after machining) to measure an actual machined shape 52R, i.e., the actual shape of component 7. The machining unit 115 is, for example, a coordinate measuring machine (CMM), a surface roughness measuring device, or a sensor.

[0163] The measuring unit 115 for a machined shape can be a measuring instrument located inside the numerically controlled machine tool 99, or a measuring instrument located outside the numerically controlled machine tool 99 can be used. For example, a measuring instrument called a touch probe is often used in a cutting machine as a measuring instrument for measuring the component shape after machining.

[0164] Alternatively, instead of measuring unit 115 for a machined shape, the system user can measure the actual machined shape 52R of component 7. In this case, instead of using a machine such as the measuring instrument, the system user can measure the shape of component 7 for each part using calipers or the like and enter the actual machined shape 52R directly into the second machining result evaluation unit 106 using the computer 23.

[0165] The second machining result evaluation unit 106 of the sixth embodiment uses the actual machined shape 52R and the design value for each part, which are stored in the part setting information 46, to calculate an actual machining defect 53R, which represents an actual machining defect for each part in the actual machined shape 52R. The second machining result evaluation unit 106 sends the actual machining defect 53R to the second result determination unit 107.

[0166] The second result determination unit 107 of the sixth embodiment determines, based on the actual machining error 53R for each part and the machining tolerance for each part, which are stored in the part setting information 46, whether the actual machining error 53R is acceptable or unacceptable. The second result determination unit 107 outputs an actual machining determination result 54R for each part, indicating whether the actual machined shape 52R (the actual machining error 53R) for each part is acceptable or unacceptable, to an external device. Furthermore, the first result determination unit 103b outputs the part determination result 50S for each part, indicating whether the simulation shape 47S (the part machining error 48S) for each part is acceptable or unacceptable, to the external device. The external device in this case is, for example, a display device.The display device shows the actual machining determination result 54R for each part and the part determination result 50S for each part.

[0167] Consequently, the system user can compare the part determination result 50S obtained through simulation for each part with the actual machining determination result 54R obtained by measuring the actual component 7 for each part. In the display unit, for example, the part determination result 50S and the actual machining determination result 54R can be displayed as tabular data for each part, superimposed as a single figure on one screen, or displayed separately as two figures.

[0168] Fig. Figure 20 is a block diagram illustrating an example of a hardware configuration of the machining system that includes the machining evaluation device according to the sixth embodiment. The machining system 1f, which includes the machining evaluation device 20f, comprises the numerically controlled machine tool 99, a conveyor 25, a measuring device 26, the computer 23 on which the machining evaluation device 20f is stored, and the network hub 24. The network hub 24 is connected to the numerically controlled machine tool 99, the conveyor 25, the measuring device 26, and the computer 23.

[0169] In machining system 1f, the conveyor 25 moves component 7, which is formed by the numerically controlled machine tool 99, to the measuring device 26. The conveyor 25 is, for example, a material handling device such as a loader, industrial robot, or the like. The conveyor 25 releases component 7 from the numerically controlled machine tool 99 and places component 7 at the measuring device 26, i.e., the measuring unit 115 for a machined shape. The measuring device 26 measures the shape of the machined object, i.e., component 7, and transmits the actual machined shape 52R, which represents the result of the measurement, via the network hub 24 to the machining evaluation device 20f.Control signals to the conveyor 25 and the measuring device 26 can be output from the computer 23 via the network hub 24 or can be output from the machine tool 99 with numerical control via a controller, such as a programmable logic controller (PLC).

[0170] It should be noted that the machining evaluation device 20f can include the model update determination unit 108, the model update execution unit 109, and the machine model DB 110, which are contained in the machining evaluation device 20e. In this case, if the accuracy of the machine model representing the machine's characteristics contained in the machine model information 45 is insufficient, the machining evaluation device 20f updates the machine model in the machine model information 45. Consequently, the machining system 1f can compare the actual machined shape 52R with the simulation shape 47S and simulate the machining error with higher accuracy.

[0171] As described above, the machining system 1f of the sixth embodiment can directly measure the actual machined shape 52R of component 7 using the measuring device 26 and can more accurately calculate the actual machining error 53R for the actual machined shape 52R.

[0172] Furthermore, the machining system 1f determines whether the actual machining error 53R, obtained from the measurement result of component 7, meets the machining tolerance or not, and outputs the actual machining determination result 54R, which indicates the result of the determination. In addition, the machining system 1f determines whether the partial machining error 48S calculated by the simulation meets the machining tolerance or not, and outputs the partial determination result 50S, which indicates the result of the determination. Consequently, the system user can easily compare the actual machining determination result 54R and the partial determination result 50S displayed on the display device. Therefore, the system user can easily compare any difference between a machining result predicted by the simulation and a machining result obtained from the measurement result of component 7. Seventh embodiment.

[0173] Next, a seventh embodiment is described with reference to the Fig. 21 and Fig. 22 described. In the seventh embodiment, the machine model information 45 is transmitted and received between a plurality of machining systems. The seventh embodiment mainly describes differences from the fifth embodiment.

[0174] Fig. Figure 21 is a block diagram illustrating an example configuration of a machining evaluation device included in a machining system according to the seventh embodiment. Components in Fig. 21, which have the same functions as those of the in Fig. The same reference numerals are used as those in 18 illustrated in machining system 1e of the fifth embodiment. Fig. 18 are assigned, and a redundant description is omitted. Fig. Figure 21 omits the illustration of the computer 23, the network hub 24 and the numerically controlled machine tool 99 contained in a machining system 1g of the seventh embodiment.

[0175] The machining system 1g of the seventh embodiment differs from the machining system 1e in that it includes a machining evaluation device 20g instead of the machining evaluation device 20e. Furthermore, the machining evaluation device 20g includes a network communication unit 112 in addition to the components contained in the machining evaluation device 20e. The network communication unit 112 is connected to the machine model database 110. The network communication unit 112 of the machining system 1g according to the seventh embodiment transmits the machine model information 45, which was collected in the machine model database 110, to an external location outside the machining system 1g. In addition, the network communication unit 112 receives the machine model information 45 transmitted from another location within the machining system 1g and stores this machine model information 45 in the machine model database 110.

[0176] It should be noted that the machining evaluation device 20g can contain the machining simulation execution unit 101a instead of the machining simulation execution unit 101b. Furthermore, the machining tolerance setting unit 100 can receive the two-dimensional CAD drawing 39 or the component shape 41 as input. Fig. Figure 21 illustrates a case in which the machining tolerance setting unit 100 receives the component shape 41 as the input.

[0177] Fig. Figure 22 is a block diagram illustrating an example of a hardware configuration of the machining system, which includes the machining evaluation device according to the seventh embodiment. As with machining system 1a, machining system 1g includes the numerically controlled machine tool 99, the computer 23, and the network hub 24 that connects the two. The computer 23 of machining system 1g stores the machining evaluation device 20g.

[0178] In the seventh embodiment, a plurality of the machining systems 1g, which include the machine tool 99 with numerical control of the same specifications, which is installed at different locations, are connected via the network hubs 24. Fig. Figure 22 illustrates a case in which the processing systems 1g are connected at two locations via the network hubs 24.

[0179] The network communication unit 112 in each of the machining systems 1g transmits the machine model information 45 to the machining system 1g outside its own machining system 1g via the network hub 24. That is, the network communication unit 112 in machining system 1g at one location transmits the machine model information 45 to the network communication unit 112 in machining system 1g at another location via the network hub 24. Consequently, the network communication unit 112 in machining system 1g at the other location receives the machine model information 45 from the network communication unit 112 in machining system 1g at the first location. Likewise, machining system 1g at the other location transmits the machine model information 45 to machining system 1g at the first location.

[0180] For example, machining system 1g is installed at one location in a test area in a domestic or overseas factory of a manufacturer of the numerically controlled machine tool, and machining system 1g is installed at another location in a factory of a user of the numerically controlled machine tool.

[0181] In the test area at the manufacturer's domestic or overseas factory of the CNC machine tool, the machine model information 45 is repeatedly updated through numerous machining tests and can thus contain the machine model of the CNC machine tool 99 with high accuracy. However, in a case where the user operates the CNC machine tool 99, which has been newly introduced, the machine model information 45 may not be sufficiently accurate. Therefore, in the seventh embodiment, the network communication unit 112 in the machining system 1g located at the CNC machine tool manufacturer's factory transmits the machine model information 45 to the network communication unit 112 in the user's machining system 1g.

[0182] It should be noted that the machine model database 110 can be located outside of the computer 23 that stores the machining evaluation device 20g. In this case, the machining evaluation device 20g temporarily stores the machine model information 45 in the machine model database 110, which is located in a data center or cloud connected to the internet instead of the computer 23. The data center or cloud can transfer the machine model information 45 to the machining evaluation device 20f via the internet at the request of the system user.

[0183] Furthermore, the machining evaluation device 20g, like the machining evaluation device 20f, can contain the machining execution unit 104f instead of the machining execution unit 104d. In this case, the machining system 1g contains the measuring unit 115 for a machined shape, and the machining evaluation device 20f does not contain the estimating unit 105 for a machined shape. With such a configuration, the model update determination unit 108 determines, based on the part determination result 50S for each part and the actual machining determination result 54R for each part, whether or not the machine model information 45 needs to be updated. Moreover, the model update execution unit 109 performs the update of the machine model information 45 using the simulation shape 47S and the actual machined shape 52R when the model update command 84 is received.

[0184] As described above, in the seventh embodiment, the plurality of machining systems 1g are connected via their respective network communication units 112, so that the machine model information 45 created at a remote location can be shared at another location. That is, the plurality of machining systems 1g can share the machine model information 45. If the plurality of machining systems 1g share the machine model information 45 with high accuracy, the machining systems 1g can predict the machining accuracy with high accuracy, regardless of the installation location and the introduction time of the machining systems 1g.

[0185] The configurations illustrated in the foregoing embodiments each represent an example, so that another known technique can be combined, the embodiments can be combined with each other, or the configurations can be partially omitted and / or modified without deviating from the scope of the present disclosure. List of reference symbols

[0186] 1a to 1g Machining system; 2 Rotary angle detector; 5 Process control; 5X to 5Z Servo control simulation unit; 6a Servo control unit; 6X to 6Z Predicted axis command; 7 Component; 9 Command value calculation unit; 14 Command value calculation simulation unit; 15 Process control simulation unit; 16X to 16Z Drive mechanism model unit; 17 Model unit for a mechanical structure; 18 Process model unit; 19 Predictive unit for a machined shape; 20a to 20g Machining evaluation device; 23 Computer; 24 Network hub; 25 Conveyor; 26 Measuring device; 31X to 31Z Predicted actuator command; 32X to 32Z Predicted axis feedback; 33X to 33Z Predicted axis position; 34X to 34Z Predicted axis disturbance; 35 Tool base position; 36 Predicted process disruption; 37 Tool tip position; 39 Two-dimensional CAD drawing; 40 Part information; 41 Component shape; 42 Machining program; 43 Tool information;44 Workpiece information; 45 Machine model information; 46 Part setup information; 47 Simulation shape; 48S Part machining error; 49 Machining execution command; 50S Part determination result; 51 Machining data; 52E Estimated machined shape; 52R Actual machined shape; 53E Estimated machining error; 53R Actual machining error; 54E Estimated determination result; 54R Actual machining determination result; 55 Predicted process command; 56 Predicted spindle current; 57 Model update history; 61a to 61c Adder / subtractor; 62 Position control; 63 Speed ​​control; 64 Current control; 65 Speed ​​calculator; 71 Motor; 72 Guide mechanism; 74 Coupling; 75a, 75b Support bearing; 76 Tool; 77 Worktable; 78 Workpiece; 79 Reduction gear; 80 Plate gauge; 81 Nut; 83 Spindle; 84 Model update command; 93X X-axis drive unit; 93Y Y-axis drive unit; 93Z Z-axis drive unit; 94 Spindle control unit;95X to 95Z Servo control; 96 Mechanical fixture unit; 97X to 97Z Drive mechanism; 98 Mechanical structure; 99 Machine tool with numerical control; 100 Machining tolerance setting unit; 101a, 101b Machining simulation execution unit; 102 First machining result evaluation unit; 103b First result determination unit; 104b, 104d, 104f Machining execution unit; 105 Estimation unit for a machined shape; 106 Second machining result evaluation unit; 107 Second result determination unit; 108 Model update determination unit; 109 Model update execution unit; 110 Machine model DB; 111 Machining condition optimization execution unit; 112 Network communication unit; 115 Measuring unit for a machined shape; 201 Processor; 202 Memory; 203 Processing circuit; HA, HB1, HB2, HC1, HC2 Hole.; QUOTES INCLUDED IN THE DESCRIPTION

[0000] This list of documents cited by the applicant was automatically generated and is included solely for the reader's convenience. The list is not part of the German patent or utility model application. The DPMA accepts no liability for any errors or omissions. Cited patent literature

[0000] JP 2013-257809

[0004]

Claims

[1] A machining evaluation device that evaluates a component shape of a component formed by a mechanical device that performs machining on a workpiece by driving an axis, the machining evaluation device comprising: a machining data setting unit for setting a machining tolerance and a design value, the machining tolerance being a tolerance regarding a machining error for each specified part, which is a part specified among parts included in the component after a machining program controlling the machining is executed; a machining simulation execution unit for executing a machining simulation of the machining using a machine model simulating a characteristic of the mechanical device and the machining program; and a first machining result evaluation unit for calculating a simulation machining error for each of the specified part based on a simulation shape and the design value, the simulation shape being predicted by the machining simulation and the component shape after the machining program is executed, the simulation machining error being a predicted value of a machining error of the simulation shape. [2] The machining evaluation device according to claim 1, further comprising a first result determination unit for determining, for each of the specified part, whether or not the simulation machining error satisfies the machining tolerance of the specified part. [3] The machining evaluation device according to claim 2, further comprising a machining condition optimization execution unit for changing at least one of the machine model and the machining program until the specified part that does not satisfy the machining tolerance is no longer included when the specified part that does not satisfy the machining tolerance is included in a result determined by the first result determination unit. [4] A machining evaluation device according to claim 2 or 3, further comprising: a machined shape estimating unit for estimating the component shape of the component formed by the machining as an estimated machined shape based on data of the mechanical device in which the machining is performed; and a second machining result evaluation unit for calculating, for each of the specified parts, an estimated machining error, that is, a machining error of the specified part, based on the machining tolerance for each of the specified parts and the estimated machined shape. [5] The machining evaluation apparatus according to claim 4, further comprising a second result determination unit for comparing the estimated machining error with the machining tolerance for each of the specified parts and determining whether or not the estimated machined shape satisfies the machining tolerance in all of the specified parts. [6] The machining evaluation device according to claim 5, further comprising: a model update determination unit for comparing a result of a determination in the first result determination unit with a result of a determination in the second result determination unit for each of the specified parts and determining, based on a comparison result, whether or not the machine model needs to be updated; and a model update execution unit for updating the machine model in a case where the model update determination unit determines that the machine model needs to be updated, wherein the machining simulation execution unit executes a machining simulation of the machining using the machining program and the updated machine model. [7] The machining evaluation device according to claim 6, wherein the model update execution unit learns a relationship between the estimated machined shape and the simulation shape using artificial intelligence and updates the machine model based on a learning result. [8] The machining evaluation device according to any one of claims 1 to 3, further comprising a second machining result evaluation unit for calculating, for each of the specified part, an actual machining error, that is, an actual machining error of the specified part, based on an actual machined shape and the machining tolerance, wherein the actual machined shape is an actual machined shape of the specified part measured by a measuring device after the machining of the workpiece is completed. [9] The machining evaluation apparatus according to claim 8, further comprising a second result determination unit for comparing the actual machining error with the machining tolerance for each of the specified parts and determining whether or not the actual machined shape satisfies the machining tolerance in all of the specified parts. [10] The machining evaluation apparatus according to claim 6 or 7, further comprising a network communication unit for transmitting the updated machine model to another machining evaluation apparatus existing in a network. [11] Processing system comprising: a mechanical device for performing machining on a workpiece by driving an axis; and a machining evaluation device for evaluating a component shape of a component formed by the mechanical device, wherein the processing evaluation device includes: a machining data setting unit for setting a machining tolerance and a design value, the machining tolerance being a tolerance of a machining error for each specified part, which is a part specified among parts included in the component after a machining program that controls machining is executed; a machining simulation execution unit for executing a machining simulation of the machining using a machine model simulating a characteristic of the mechanical device and the machining program; a first machining result evaluation unit for calculating a simulation machining error for each of the specified part based on a simulation shape and the design value, the simulation shape being predicted by the machining simulation and the component shape after the machining program is executed, the simulation machining error being a predicted value of a machining error of the simulation shape; and a first result determination unit for determining, for each of the specified parts, whether the simulation machining error satisfies the machining tolerance of the specified part or not; and the mechanical device comprises a machining execution unit for executing machining of the workpiece using the machining program in a case where the first result determination unit determines that the simulation machining error satisfies the machining tolerance in all of the specified parts. [12] The machining system according to claim 11, further comprising a network communication unit for transmitting the updated machine model to another machining system present in a network. [13] A machining evaluation method that evaluates a component shape of a component formed by a mechanical device that performs machining on a workpiece by driving an axis, the machining evaluation method comprising: a machining data setting step in which a machining evaluation device sets a machining tolerance and a design value, the machining tolerance being a tolerance of a machining error for each specified part, which is a part specified among parts included in the component, after a machining program that controls the machining is executed; a machining simulation execution step in which the machining evaluation device executes a machining simulation of the machining using a machine model simulating a characteristic of the mechanical device and the machining program; a first machining result evaluation step in which the machining evaluation device calculates a simulation machining error for each of the specified part based on a simulation shape and the design value, the simulation shape being predicted by the machining simulation and the component shape after the machining program is executed, the simulation machining error being a predicted value of a machining error of the simulation shape; a first result determination step in which the machining evaluation device determines for each of the specified parts whether the simulation machining error satisfies the machining tolerance of the specified part or not; and a machining execution step in which the mechanical device executes machining of the workpiece using the machining program in a case where it is determined that the simulation machining error satisfies the machining tolerance in all of the specified parts.

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