Digital projector, machine tool and projected image display method

Abstract

To secure a wide visual field and furthermore to perform highly accurate measurement.SOLUTION: A digital projector of one embodiment comprises: a light source irradiating a workpiece with light; a low magnification camera mechanism imaging a projected image of the workpiece generated by irradiation from the light source; a beam splitter provided on the optical path of the projected image; a high magnification camera mechanism imaging a projected image having been divided by the beam splitter in a narrow range than the low magnification camera mechanism and with a higher magnification than the low magnification camera mechanism; and a display displaying a low magnification image captured by the low magnification camera mechanism and a high magnification image captured by the high magnification camera mechanism. The high magnification camera mechanism includes a high magnification image-forming lens that expands the projected image at a prescribed magnification, a camera for high magnification that captures an expanded projected image, and a movement mechanism for the camera for high magnification that changes the imaging position of the camera for high magnification with respect to a projected image.SELECTED DRAWING: Figure 2

Description

Technical Field

[0001] The present invention relates to a digital projector, a machine tool, and a projection image display method.

Background Art

[0002] Conventionally, an image of the tip shape of a grinding wheel captured by a camera is simultaneously displayed on a display screen showing the machining shape of a workpiece, and the image of the tip shape of the grinding wheel is relatively moved with respect to the machining shape of the workpiece displayed on the display screen, and a tracing grinding machine that performs teaching by obtaining the positions of a plurality of contacted locations is known (Patent Document 1).

[0003] In the tracing grinding machine of Patent Document 1, a scaling icon is displayed on the display screen, and by operating this scaling icon, it is possible to enlarge and reduce an image of the machining shape of the workpiece, an image of the tip shape of the grinding wheel, etc. displayed on the display screen.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0005] In recent years, processed products such as mold parts and tools have become increasingly miniaturized and highly precise. Along with this, tracing grinding machines are required to perform grinding processing and workpiece shape measurement in micron units. In the tracing grinding machine of Patent Document 1, although it is possible to enlarge various images with the scaling icon, since it only enlarges a part of an image captured at a low magnification for widening the field of view by image processing, even if an image captured using a high-resolution camera (so-called 4K camera, 8K camera, etc., high-pixel camera) at the time of the present application is used, it is difficult to perform highly precise measurement in micron units.

[0006] In addition, in the optical copying grinding machine of Patent Document 1, when the magnification of the camera is increased to the extent that it can be measured in microns, the field of view (imaging range) becomes extremely narrow, and it is difficult to determine which part of the workpiece or grinding wheel is being observed in the image displayed on the display screen. There is also a risk that problems may occur, such as the image on the display screen changing greatly just by slightly moving the workpiece or grinding wheel to change the observation part, and it is easy to lose the observation part.

[0007] One aspect of the present invention is a digital projector, a machine tool, and a projection image display method capable of performing high-precision measurement while ensuring a wide field of view.

Means for Solving the Problems

[0008] The digital projector according to one aspect of the present invention includes a light source that irradiates light onto a workpiece, a low-magnification camera mechanism that images a projection image of the workpiece generated by the irradiation from the light source, a beam splitter provided on the optical path of the projection image, a high-magnification camera mechanism that images the projection image split by the beam splitter in a range narrower than that of the low-magnification camera mechanism and at a higher magnification than that of the low-magnification camera mechanism, and a display that displays a low-magnification image imaged by the low-magnification camera mechanism and a high-magnification image imaged by the high-magnification camera mechanism. The high-magnification camera mechanism includes a high-magnification imaging lens that enlarges the projection image to a predetermined magnification, a high-magnification camera that images the enlarged projection image, and a high-magnification camera movement mechanism that changes the imaging position of the high-magnification camera with respect to the projection image.

[0009] In addition, the machine tool according to one aspect of the present invention includes such a digital projector.

[0010] Furthermore, the projection image display method according to one aspect of the present invention is a projection image display method using the digital projector described above, and includes a light irradiation step of irradiating light onto a workpiece, a low-magnification imaging step of imaging a projection image of the workpiece generated by the light irradiation step with the low-magnification camera mechanism, a high-magnification imaging step of imaging the projection image split by the beam splitter with the high-magnification camera mechanism in a range narrower than that of the low-magnification camera mechanism and at a higher magnification than that of the low-magnification camera mechanism, and a display step of displaying the low-magnification image captured by the low-magnification imaging step and the high-magnification image captured by the high-magnification imaging step on the display.

[0011] According to the digital projector, the machine tool, and the projection image display method according to one aspect of the present invention, it is possible to observe a wide range of the projection image of the workpiece by the low-magnification image captured by the low-magnification camera mechanism, and to observe a more pinpoint range in the projection image of the workpiece at a higher magnification by the high-magnification image captured by the high-magnification camera mechanism.

Effects of the Invention

[0012] According to one aspect of the present invention, high-precision measurement can be performed while securing a wide field of view.

Brief Description of the Drawings

[0013]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Embodiments for Carrying Out the Invention

[0014] Hereinafter, preferred embodiments for carrying out the present invention will be described with reference to the drawings. It should be noted that the following embodiments do not limit the invention according to each claim, and not all combinations of the features described in the embodiments are essential for the solution means of the invention. Further, in the present embodiment, there are cases where the scales and dimensions of each component are exaggeratedly shown, and cases where some components are omitted.

[0015] [Overall Configuration of Machine Tool] First, the overall configuration of the machine tool according to the present embodiment will be described with reference to FIG. 1. FIG. 1 is a diagram schematically showing the overall configuration of the machine tool according to the present embodiment. In the following description, it is described that the machine tool according to the present embodiment is an optical copying grinding machine, but it is not limited thereto, and other machine tools may be used as long as they are machine tools with a digital projector. Further, in the following description, the "X-axis direction" means the direction perpendicular to the plane of FIG. 1, the "Z-axis direction" means the vertical direction in FIG. 1, and the "Y-axis direction" means the left-right direction in FIG. 1.

[0016] As shown in FIG. 1, the optical copying grinding machine 1 according to the present embodiment includes a work holding mechanism 10 that holds a work W to be machined, a grindstone holding mechanism 20 that holds a grindstone 22 for grinding the work W on the work holding mechanism 10, a digital projector 30 capable of enlarging and displaying the work W, and an operation control panel 70 that can input and register various information related to grinding and automatically controls the optical copying grinding machine 1 based on a predetermined machining program. It should be noted that since the operation control panel 70 according to the present embodiment can adopt various known configurations, a detailed description thereof is omitted.

[0017] As shown in FIG. 1, the work holding mechanism 10 includes a work table 12 on which a work W is placed, and an X-axis direction moving mechanism 14, a Y-axis direction moving mechanism 16, and a Z-axis direction moving mechanism 18 that move the work table 12 in the X-axis direction, Y-axis direction, and Z-axis direction respectively by automatic control based on an operator's operation or a machining program. These X-axis direction moving mechanism 14, Y-axis direction moving mechanism 16, and Z-axis direction moving mechanism 18 are each provided with an operation handle (not shown) operated by an operator, and are configured to move the work W along the X-axis direction, Y-axis direction, and Z-axis direction by the operator's operation via the operation handle. Note that since the work holding mechanism 10 according to the present embodiment can adopt various known configurations, a detailed description thereof is omitted.

[0018] As shown in FIG. 1, the grindstone holding mechanism 20 includes a grindstone head 24 that rotatably supports a grindstone 22, and an X-axis direction moving mechanism 25 and a Y-axis direction moving mechanism 26 that move the grindstone head 24 in the X-axis direction and Y-axis direction respectively by automatic control based on an operator's operation or a machining program. The grindstone head 24 supports the grindstone 22 so as to be movable along the Z-axis direction, and is configured to also function as a Z-axis direction moving mechanism of the grindstone 22. The X-axis direction moving mechanism 25 is provided with an X-axis handle 27 operated by an operator, and is configured to move the grindstone 22 along the X-axis direction by the operator's operation via the X-axis handle 27. Further, the Y-axis direction moving mechanism 26 is provided with a Y-axis handle 28 operated by an operator, and is configured to move the grindstone 22 along the Y-axis direction by the operator's operation via the Y-axis handle 28. Note that since the grindstone holding mechanism 20 according to the present embodiment can adopt various known configurations, a detailed description thereof is omitted.

[0019] The optical copying grinding machine 1 according to this embodiment is configured to be able to position the workpiece W placed on the worktable 12 in the X-axis direction, Y-axis direction, and Z-axis direction by manual operation or automatic control based on a machining program. Further, the optical copying grinding machine 1 is configured to be able to perform grinding on the workpiece W by bringing the grinding wheel 22 rotated at a predetermined rotational speed into contact with the workpiece W while moving it in the X-axis direction, Y-axis direction, and Z-axis direction by manual operation or automatic control based on a machining program.

[0020] [Overall Configuration of Digital Projector] Next, the specific configuration of the digital projector 30 according to this embodiment will be described with reference to FIGS. 2 to 5. FIG. 2 is a diagram schematically showing the optical configuration of the digital projector. FIG. 3 is a diagram schematically showing the configuration of the high-magnification camera moving mechanism. FIG. 4 is a diagram schematically showing the system configuration of the digital projector. FIG. 5 is a diagram schematically showing the movable range of the high-magnification image with respect to the low-magnification image.

[0021] As shown in FIG. 2, the digital projector 30 includes a main light source 32 (light source) such as an LED that irradiates a subject, which is the workpiece W (workpiece to be machined), with a light beam BM (light), a low-magnification camera mechanism 40 that captures a projected image of the workpiece W generated by the irradiation from the main light source 32, a beam splitter 36 provided on the optical path of the projected image, a high-magnification camera mechanism 50 that captures the projected image of the workpiece W split by the beam splitter 36 in a range narrower than that of the low-magnification camera mechanism 40 and at a higher magnification than that of the low-magnification camera mechanism 40, and a display 31 (see FIG. 1) that displays the low-magnification image LI captured by the low-magnification camera mechanism 40 and the high-magnification image HI captured by the high-magnification camera mechanism 50. Further, as shown in FIG. 4, the digital projector 30 further includes a projector control unit 60 that executes various processes in the digital projector 30. Note that since various known configurations can be adopted for the main light source 32 according to this embodiment, a detailed description thereof will be omitted.

[0022] Further, as shown in FIG. 2, the digital projector 30 includes a relay lens 33 and a reflecting mirror 35 that transmit the projected images (shadows) of the workpiece W and the grindstone 22 generated by the irradiation from the main light source 32 to the beam splitter 36 between the workpiece W and the beam splitter 36. Further, the digital projector 30 may be provided with various lenses (condenser lens group), dust-proof glass, etc. between the main light source 32 and the workpiece W and the grindstone 22 as required. Note that the relay lens 33 may be a lens group composed of a plurality of lenses.

[0023] In the present embodiment, the beam splitter 36 is arranged at a position where the projected image of the subject, which is the workpiece W (workpiece to be processed), generated by the irradiation from the main light source 32 is formed. Further, the relay lens 33 and the reflecting mirror 35 are configured to cooperate with each other to form the projected images of the workpiece W and the grindstone 22 on the beam splitter 36. Thus, in the present embodiment, the projected image is formed within the beam splitter 36, whereby an intermediate focal point is formed on the optical path between the workpiece W (workpiece to be processed) and the low-magnification camera mechanism 40 and / or the high-magnification camera mechanism 50. However, the present invention is not limited to this, and any optical path configuration that finally forms the image of the workpiece W (workpiece to be processed) as the subject on the low-magnification camera mechanism 40 and the high-magnification camera mechanism 50 may be used. From this perspective, the position where the beam splitter 36 is arranged is not particularly limited as long as it is on the workpiece W (workpiece to be processed) side of the low-magnification camera mechanism 40 and the high-magnification camera mechanism 50. For example, instead of the configuration using the intermediate focal point at an intermediate position including the beam splitter 36 (the present embodiment), a configuration in which the collimated light by the beam splitter 36 is adjusted in the optical path may be used.

[0024] In this embodiment, the beam splitter 36 is disposed between the reflecting mirror 35, the low-magnification camera mechanism 40, and the high-magnification camera mechanism 50, and includes a transmitted-light exit surface that divides and transmits the formed projection image (optical path), and a reflected-light exit surface that changes the direction of the formed projection image (optical path) and reflects and divides it. As the beam splitter 36, for example, a half mirror, a partial mirror, or the like can be used. The digital projector 30 according to this embodiment is configured to be able to simultaneously observe the same region (projection image) at different magnifications with the low-magnification camera mechanism 40 and the high-magnification camera mechanism 50 by including such a beam splitter 36.

[0025] Furthermore, as shown in FIG. 2, the digital projector 30 further includes a light source 37 for reflected image and a beam splitter 34 for reflected image. The light source 37 for reflected image is a light source such as an LED, for example, and is configured to be able to irradiate the light beam BM'. The beam splitter 34 for reflected image is disposed between the workpiece W, the grindstone 22, and the reflecting mirror 35, and transmits the light beam BM irradiated from the main light source 32 toward the reflecting mirror 35, and reflects the light beam BM' irradiated from the light source 37 for reflected image toward the workpiece W and the grindstone 22. As the beam splitter 34 for reflected image, for example, a half mirror or the like can be used. These the light source 37 for reflected image and the beam splitter 34 for reflected image cooperate with each other to illuminate the workpiece W and the grindstone 22 from a direction opposite to the irradiation direction of the main light source 32 (upward in this embodiment), and also form an image of the reflected image from above the workpiece W in the beam splitter 36 (or transmit or reflect and divide the optical path). Note that since various known configurations can be adopted for the light source 37 for reflected image and the beam splitter 34 for reflected image according to this embodiment, detailed description thereof is omitted.

[0026] [Configuration of Low-Magnification Camera Mechanism] The low-magnification camera mechanism 40 is configured to image either the projected image that has passed through the beam splitter 36 and been split or the projected image that has been reflected and split. Specifically, as shown in FIG. 2, the low-magnification camera mechanism 40 includes a low-magnification camera 42 and a low-magnification imaging lens 44 that transmits the projected image that has passed through the beam splitter 36 to the low-magnification camera 42. In the illustrated example, the low-magnification imaging lens 44 and the low-magnification camera 42 are arranged to face the transmissive light exit surface of the beam splitter 36, but the present invention is not limited thereto, and various arrangements are possible. Further, appropriate components such as reflection means can be added according to the arrangement.

[0027] The low-magnification imaging lens 44 is configured to magnify or reduce the projected image that has passed through the beam splitter 36 at a predetermined magnification and form an image of the magnified or reduced projected image (low-magnification projected image) on the low-magnification camera 42. The low-magnification imaging lens 44 may be a lens group (low-magnification imaging lens group) composed of a plurality of lenses. The magnification of the low-magnification imaging lens 44 can be arbitrarily set as long as it is a magnification that can capture the processing range of the workpiece W relatively widely. For example, it can be set to about 0.3 to 1 times the actual size of the workpiece W and the grinding wheel 22. Note that the magnification of the low-magnification imaging lens 44 may be arbitrarily changed by switching or adding / removing the lenses used.

[0028] The low-magnification camera 42 is configured to be able to image the low-magnification projected image formed by the low-magnification imaging lens 44. As the low-magnification camera 42, for example, a so-called 4K camera having a 4K resolution can be used, but the present invention is not limited thereto. As the low-magnification camera 42, various known imaging means such as a CMOS sensor, a CCD sensor, an array sensor, and an image pickup tube can be arbitrarily adopted. Further, the low-magnification camera 42 is connected to the projector control unit 60 so as to be able to transfer data wirelessly or by wire, and transfers the image data of the low-magnification projected image captured by the low-magnification camera 42 to the projector control unit 60 and is configured to display it as a low-magnification image LI on the display 31.

[0029] [Configuration of High-Power Camera Mechanism] The high-power camera mechanism 50 is configured to image either the projected image that has passed through the beam splitter 36 and been split or the other projected image that has been reflected and split by the beam splitter 36. Specifically, as shown in FIG. 2, the high-power camera mechanism 50 includes a high-power imaging lens 54 that magnifies the projected image reflected and split by the beam splitter 36 at a predetermined magnification, a high-power camera 52 that images the magnified projected image (high-power projected image) by the high-power imaging lens 54, and a high-power camera movement mechanism 57 that changes the imaging position of the high-power camera 52 with respect to the projected image reflected and split by the beam splitter 36 (the reflection light exit surface of the beam splitter 36).

[0030] Further, the high-power camera mechanism 50 further includes a reflecting mirror 56 that reflects the high-power projected image magnified by the high-power imaging lens 54 toward the high-power camera 52. In the illustrated example, the high-power imaging lens 54 is arranged so as to face the reflection light exit surface of the beam splitter 36, and the high-power camera 52 is arranged in a direction orthogonal to this facing direction. However, it is not limited to this, and various arrangements are possible. Also, it is possible to add or remove the reflecting mirror 56 according to the arrangement.

[0031] The high-power imaging lens 54 is configured to magnify the projected image reflected and split by the beam splitter 36 at a predetermined magnification and form the high-power projected image on the high-power camera 52. The high-power imaging lens 54 may be a lens group (high-power imaging lens group) composed of a plurality of lenses. The magnification of the high-power imaging lens 54 is set to be higher than the magnification of the low-power imaging lens 44. Such a magnification can be arbitrarily set within a range where it is possible to pinpoint the workpiece W. For example, it can be set to a magnification that can magnify the workpiece W and the grinding wheel 22 by about 5 to 10 times with respect to the actual objects. Note that the magnification of the high-power imaging lens 54 may be arbitrarily changeable by switching or adding / removing the lenses used.

[0032] The high-magnification camera 52 is configured to be able to capture a high-magnification projection image that is enlarged and imaged by the high-magnification imaging lens 54. The high-magnification camera 52 can use, for example, a so-called 2K camera having a 2K resolution, but is not limited thereto. As the high-magnification camera 52, various known imaging means such as a CMOS sensor, a CCD sensor, an array sensor, and an image pickup tube can be arbitrarily adopted. Further, the high-magnification camera 52 is connected to the projector control unit 60 so as to be able to transfer data wirelessly or wiredly, and transfers the image data of the high-magnification projection image captured by the high-magnification camera 52 to the projector control unit 60, and is configured to be displayed on the display 31 as the high-magnification image HI.

[0033] The high-magnification camera moving mechanism 57 is configured to change the imaging position of the high-magnification camera 52 according to the movement (change of the display position) of the high-magnification image HI described later. Specifically, the high-magnification camera moving mechanism 57 is configured to be able to change the imaging position of the high-magnification camera 52 with respect to the reflected light emission surface of the beam splitter 36 while maintaining the relative positional relationship among the high-magnification imaging lens 54, the high-magnification camera 52, and the reflecting mirror 56. More specifically, as shown in FIG. 3, the high-magnification camera moving mechanism 57 includes a movable housing 58 configured to be relatively movable with respect to the fixed housing 11 incorporating the beam splitter 36, and an X-axis direction driving unit 59x (see FIG. 4) and a Y-axis direction driving unit 59y (see FIG. 4) that move the movable housing 58 along directions (the X-axis direction and the Y-axis direction in FIG. 3) orthogonal to the direction (the Z-axis direction in FIG. 3) in which the reflected light emission surface of the beam splitter 36 and the high-magnification imaging lens 54 face each other.

[0034] In the fixed housing 11, in addition to the beam splitter 36, a relay lens 33, a reflecting mirror 35, a beam splitter 34 for reflected image, and a light source 37 for reflected image are stored in a state where they are immovable relative to each other. Further, in the fixed housing 11, a low-magnification camera mechanism 40 is incorporated in a state where it is immovable relative to the transmission light exit surface of the beam splitter 36. However, the low-magnification camera mechanism 40 may be movable relative to the transmission light exit surface of the beam splitter 36, that is, the imaging range of the projected image transmitted through and split by the transmission light exit surface of the beam splitter 36 may be changeable.

[0035] In the movable housing 58, a high-magnification imaging lens 54, a high-magnification camera 52, and a reflecting mirror 56 are stored in a state where they are immovable relative to each other. The movable housing 58 is configured to be movable relative to the reflected light exit surface of the beam splitter 36 incorporated in the fixed housing 11, whereby the imaging range of the high-magnification camera 52 with respect to the projected image reflected and split by the beam splitter 36 can be changed.

[0036] The X-axis direction drive unit 59x is configured to move the movable housing 58 along the X-axis direction (a first direction orthogonal to the direction in which the reflected light exit surface of the beam splitter 36 and the high-magnification imaging lens 54 face each other) with respect to the fixed housing 11 based on an X-axis direction movement command output in response to an operation instruction of an operator. Further, the Y-axis direction drive unit 59y is configured to move the movable housing 58 along the Y-axis direction (a direction orthogonal to the direction in which the reflected light exit surface of the beam splitter 36 and the high-magnification imaging lens 54 face each other and the first direction) with respect to the fixed housing 11 based on a Y-axis direction movement command output in response to an operation instruction of an operator. Note that since various known configurations can be adopted for the X-axis direction drive unit 59x and the Y-axis direction drive unit 59y according to the present embodiment, detailed description thereof is omitted.

[0037] [Configuration of Display] The display 31 has a display area capable of displaying a low-magnification image LI captured by the low-magnification camera mechanism 40 and a high-magnification image HI captured by the high-magnification camera mechanism 50. The display area of the display 31 is constituted by a touch panel capable of receiving an operation instruction from an operator. Note that the display 31 is not limited to a touch panel, and various arbitrary configurations such as a liquid crystal display can be adopted. Also, in the illustrated example, the display 31 is an installed-type display fixedly provided on the main body portion of the digital projector 30, but is not limited thereto, and may be a remote-type display installed at a position separated from the main body portion of the digital projector 30, or may be a portable display such as a tablet terminal, for example. Further, as operations by the operator, for example, various operations such as touch, swipe, pinch open, and pinch close on the touch panel are exemplified, but are not limited thereto, and operation means (for example, a mouse, a keyboard, and a jog) provided separately from the display 31 may be used.

[0038] [Configuration of Projector Control Unit] As shown in FIG. 4, the projector control unit 60 includes a screen display processing unit 62 that controls the screen display processing of the display 31, a drive processing unit 64 that controls the high-magnification camera movement mechanism 57 according to an operation instruction from an operator, and a storage unit 66 that stores various information and programs for operating the projector control unit 60. Specifically, the projector control unit 60 includes a CPU, which is a hardware processor, a RAM, a ROM, etc., expands the program stored in the storage unit 66 into the RAM, and interprets and executes this by the CPU, thereby being configured to realize the functions of the screen display processing unit 62 and the drive processing unit 64.

[0039] The screen display processing unit 62 is configured to simultaneously display the low-magnification image LI captured by the low-magnification camera mechanism 40 and the high-magnification image HI captured by the high-magnification camera mechanism 50 on the display 31. Specifically, the screen display processing unit 62 performs preprocessing such as inversion processing on the image data acquired from the low-magnification camera mechanism 40 as needed, and then executes a process of enlarging and displaying the preprocessed image data as the low-magnification image LI over substantially the entire area of the display 31. Further, the screen display processing unit 62 performs preprocessing such as inversion processing on the image data acquired from the high-magnification camera mechanism 50 as needed, and then executes a process of enlarging and displaying the preprocessed image data as the high-magnification image HI in a part of the display 31.

[0040] Here, the low-magnification image LI is an image that displays the projection image transmitted through and split by the beam splitter 36 at a predetermined magnification, and the high-magnification image HI is an image that displays a part of the projection image reflected and split by the beam splitter 36 at a magnification higher than that of the low-magnification image LI. The shapes (aspect ratios) of the window for displaying the low-magnification image LI and the window for displaying the high-magnification image HI may be the same or different. Further, the shapes (aspect ratios) of the respective windows for displaying these low-magnification image LI and high-magnification image HI may be the same as or different from the display area of the display 31.

[0041] In addition, the screen display processing unit 62 is configured to be able to display the low-magnification image LI and the high-magnification image HI superimposed on the display 31. Specifically, as shown in FIG. 5, the screen display processing unit 62 performs origin alignment of the low-magnification image LI and the high-magnification image HI at a predetermined reference point, and is configured to display the high-magnification image HI superimposed on the low-magnification image LI. Examples of the reference point in this case include the center (0, 0) of the low-magnification image LI and the center (0, 0) of the high-magnification image HI, but are not limited thereto, and the corners of the low-magnification image LI and the high-magnification image HI may be used as the reference point. Further, the screen display processing unit 62 converts the coordinate position (mechanical coordinate position) of the high-magnification camera moving mechanism 57 into the coordinate position (coordinate position on the screen) on the display 31, and displays the high-magnification image HI at the converted coordinate position on the screen, so that the high-magnification image HI can be displayed on the corresponding portion of the low-magnification image LI. That is, as shown in FIG. 4, the screen display processing unit 62 is configured to be able to display the high-magnification image HI indicating the shape of the part (high-magnification projection image) superimposed on a part of the low-magnification projection image indicated by the low-magnification image LI. Note that the screen display processing unit 62 may be configured to be able to switch the display and non-display of the high-magnification image HI by the operation of the operator. Further, the screen display processing unit 62 may be configured to be able to change the display size of the high-magnification image HI.

[0042] Furthermore, the screen display processing unit 62 is configured to be able to display the machining support image data (for example, line drawing data) stored in advance in the storage unit 66 superimposed on the low-magnification image LI and the high-magnification image HI. Specifically, the screen display processing unit 62 is configured to be able to display the machining support image data corresponding to the low-magnification projection image of the low-magnification image LI at the same magnification as the low-magnification projection image on the low-magnification image LI, and is configured to be able to display the machining support image data corresponding to the high-magnification projection image of the high-magnification image HI at the same magnification as the high-magnification projection image on the high-magnification image HI. Examples of such machining support image data include a chart showing the desired shape (shape to be ground) of the work W (workpiece), but are not limited thereto, and may be various template figures such as a straight line figure or an arc figure.

[0043] In addition, the screen display processing unit 62 is configured to be able to execute a process of enlarging or reducing the low-magnification image LI and the high-magnification image HI on the display 31 by the operation of the operator. Further, the screen display processing unit 62 is configured to enlarge or reduce the machining support image data at the same magnification in conjunction with the enlargement or reduction of the low-magnification image LI and the high-magnification image HI. Note that the screen display processing unit 62 may be configured to be able to execute a process of independently enlarging or reducing the low-magnification image LI and the high-magnification image HI, or alternatively or together with this, may be configured to be able to execute a process of enlarging or reducing the low-magnification image LI and the high-magnification image HI in conjunction. Such an enlargement or reduction operation is exemplified by, for example, an operation through a touch on an enlargement button and a reduction button displayed on the display 31, or an operation such as pinch open and pinch close on the low-magnification image LI and the high-magnification image HI on the display 31, but is not limited thereto.

[0044] Furthermore, the screen display processing unit 62 is configured to be able to change the display position of the high-magnification image HI on the display 31. Specifically, the screen display processing unit 62 is configured to be able to execute a process of moving the high-magnification image HI on the display 31 by the operation of the operator. Also, the screen display processing unit 62 is configured to move the machining support image data the same distance in conjunction with the movement of the high-magnification image HI. As shown in FIG. 5, the movement range of the high-magnification image HI can be set to a range where the center (0, 0) of the high-magnification image HI does not exceed the four corners of the low-magnification image LI, but is not limited thereto. Also, the movement range of the high-magnification image HI (the movable range of the high-magnification camera movement mechanism 57) may coincide with or be different from the shape (aspect ratio) of the display area of the display 31.

[0045] Note that the screen display processing unit 62 may be configured to be capable of executing a process of moving the low-magnification image LI within the display 31 by an operator's operation. In this case, it may also be possible to execute a process of moving the high-magnification image HI and the machining support image data on the display 31 in conjunction with the movement of the low-magnification image LI. Further, the screen display processing unit 62 may be configured to be capable of switching between a linked movement mode in which other images or image data are moved in conjunction with the movement target (high-magnification image HI, low-magnification image LI, or machining support image data) and an independent movement mode in which each element is moved independently of each other. Such a movement operation is exemplified by a swipe operation on the display 31, but is not limited thereto, and may be executed by an operation of touching the movement destination, a touch operation on a movement operation button displayed on the display 31, or an operation using operation means (for example, a mouse, a keyboard, and a jog) provided separately from the display 31.

[0046] In addition, the screen display processing unit 62 may be configured to be capable of executing a process of moving the low-magnification image LI, the high-magnification image HI, and the machining support image data on the display 31 in conjunction with the movement of the work W by the work holding mechanism 10. Specifically, the screen display processing unit 62 acquires the coordinate position of the work W from the work holding mechanism 10, calculates the movement amount of the work W, converts the movement amount into a movement amount on the display 31 based on a predetermined setting magnification, and may be configured to be capable of executing a process of moving the low-magnification image LI, the high-magnification image HI, and the machining support image data based on the converted movement amount.

[0047] In addition to the various processes described above, the screen display processing unit 62 may be configured to be capable of executing processes such as displaying and adjusting auxiliary lines (such as cross lines and extension lines displayed on the curved portions of the chart diagram) on the chart diagram, displaying concentric circles necessary for aligning the grinding wheel position, measuring the shape of the workpiece W (for example, the distance between any two points, linear angle, arc radius, step difference, pitch, and the difference amount with respect to CAD data, etc.), measuring the tip shape of the grinding wheel transferred to a dummy workpiece or the like, simulation processing for superimposing and displaying the grinding wheel movement path in the machining program on the real image (low magnification image LI and high magnification image HI), and correction processing of the machining program.

[0048] Furthermore, the screen display processing unit 62 may be configured to be capable of executing a process of automatically measuring the shape of the workpiece W (workpiece shape automatic measurement process) using the measurement position indicated by the CAD data in advance. Also, the screen display processing unit 62 may be configured to be capable of displaying the result of the workpiece shape automatic measurement process on the display 31 simultaneously with the low magnification image LI, high magnification image HI, chart diagram, etc. The result of the workpiece shape automatic measurement process may be performed, for example, by a method of visually displaying the dimensional difference between the measured dimensions of the workpiece contour portion and the desired shape which is the finished shape. Also, in this case, the allowable tolerance may be visually displayed simultaneously with the dimensional difference. Such display of the allowable tolerance is exemplified, for example, by a method of simultaneously displaying an inner allowable tolerance chart diagram showing the allowable shape on the minus side (inside of the workpiece W) and an outer allowable tolerance chart diagram showing the allowable shape on the plus side (outside of the workpiece W) with respect to the outer contour line of the desired shape. According to such a configuration, a double frame line is formed and displayed by the inner allowable tolerance chart diagram (inner frame line) and the outer allowable tolerance chart diagram (outer frame line), and the range between this double frame line is the range of the allowable tolerance. Therefore, it is possible to easily determine whether or not the result of the workpiece shape automatic measurement process is within the range of the allowable tolerance only by visually confirming whether or not the dimensional difference as the measurement result is included between the double frame lines. Note that the screen display processing unit 62 may be configured to be capable of reading out and displaying the past results stored in the storage unit 66.

[0049] The drive processing unit 64 is configured to control the high-magnification camera moving mechanism 57 in response to the movement operation of the high-magnification image HI by the operator. Specifically, when a movement command operation of the high-magnification image HI by the operator is input, the drive processing unit 64 is configured to convert the operation movement amount (the movement amount of the screen coordinates) of the high-magnification image HI on the display 31 into the X'Y'-axis movement amount (the movement amount of the mechanical coordinates) of the high-magnification camera moving mechanism 57. Further, the drive processing unit 64 is configured to drive the X-axis drive unit 59x and the Y-axis drive unit 59y of the high-magnification camera moving mechanism 57 based on the converted X'Y'-axis movement amount, and is capable of executing a process of capturing the high-magnification image HI with the high-magnification camera 52. Then, the screen display processing unit 62 is configured to re-display the high-magnification image HI captured in this way on the display 31, so that the above-described movement process of the high-magnification image HI is executed. In this case, examples of the conversion include, but are not limited to, a conversion method of multiplying a relative amount on the touch panel by a conversion coefficient. Further, the drive processing unit 64 may capture the high-magnification image HI in real time even during the movement of the high-magnification camera moving mechanism 57, or may capture the high-magnification image HI after the movement of the high-magnification camera moving mechanism 57.

[0050] By having the above configuration, the digital projector 30 can perform the grinding process of the work W while simultaneously viewing the low-magnification image LI and the high-magnification image HI so that their shapes match. Further, the digital projector 30 can also simultaneously project the projection image of the grinding wheel 22 and the processing support image data such as a chart diagram onto the display 31 and teach (measure and register) the grinding wheel position along the contour of the chart diagram in the creation of the processing program by the teaching playback method.

[0051] [Projection Image Display Method] Next, a projection image display method using the digital projector 30 according to the present embodiment will be described with reference to FIG. 6. FIG. 6 is a flowchart showing an example of the projection image display method according to the present embodiment.

[0052] The projection image display method according to this embodiment generally includes a light irradiation step (S1) of irradiating a workpiece W (workpiece) with a light beam BM (light), a low-magnification imaging step (S2) of imaging the projection image of the workpiece W generated by the light irradiation step with a low-magnification camera mechanism 40, a high-magnification imaging step (S3) of imaging the projection image split by a beam splitter 36 with a high-magnification camera mechanism 50 in a range narrower than that of the low-magnification camera mechanism 40 and at a higher magnification than that of the low-magnification camera mechanism 40, and a display step (S4) of displaying a low-magnification image LI imaged by the low-magnification imaging step (S2) and a high-magnification image HI imaged by the high-magnification imaging step (S3) on a display 31.

[0053] Specifically, first, when the power is turned on by an operator, a light beam BM (light) is irradiated from a main light source 32 (S1: light irradiation step). As a result, shadows of the workpiece W and the grindstone 22 are formed, and the shadows are transmitted or reflected through the beam splitter 36 via a relay lens 33 and a reflector 35 and then imaged, thereby forming projection images of the workpiece W and the grindstone 22. In the projection image display method according to this embodiment, the reflection images from above the workpiece W and the grindstone 22 are also transmitted or reflected through the beam splitter 36 and split and imaged by a reflection image light source 37 and a reflection image beam splitter 34.

[0054] Next, the low-magnification camera mechanism 40 is activated, and the projection image transmitted through the beam splitter 36 and split and imaged is imaged by the low-magnification camera mechanism 40 (S2: low-magnification imaging step). In parallel with this low-magnification imaging step (S2), the high-magnification camera mechanism 50 is activated, and the projection image reflected by the beam splitter 36 and split and imaged is imaged by the high-magnification camera mechanism 50 (S3: high-magnification imaging step).

[0055] Then, the image data captured in the low-magnification imaging step (S2) and the image data captured in the high-magnification imaging step (S3) are respectively transferred to the screen display processing unit 62, subjected to predetermined preprocessing, and the image data captured in the low-magnification imaging step (S2) is displayed as a low-magnification image LI over substantially the entire area of the display 31, and the image data captured in the high-magnification imaging step (S3) is displayed as a high-magnification image HI in a part of the display 31 (S4: display step).

[0056] Thereby, while observing a wide range (e.g., the whole) of the projection image by the low-magnification image LI, it is possible to magnify and display a more pinpoint range in the projection image at a high magnification by the high-magnification image HI to observe the workpiece details and measure the shape dimensions. Also, in the projection image display method according to the present embodiment, the above-described image data for machining support can be displayed on the display 31 together with the low-magnification image LI and the high-magnification image HI.

[0057] Also, in the projection image display method according to the present embodiment, when it is detected that the display position of the high-magnification image HI has been changed by the operation of the operator in a state where the low-magnification image LI and the high-magnification image HI are simultaneously displayed on the display 31 (YES in S5), the operation movement amount (the movement amount of the screen coordinates) of the high-magnification image HI on the display 31 is converted into the X'Y' axis movement amount (the movement amount of the mechanical coordinates) of the high-magnification camera movement mechanism 57 (S6), and the high-magnification camera movement mechanism 57 is moved based on the converted X'Y' axis movement amount (S7), and the projection image reflected and split by the beam splitter 36 and imaged is imaged again by the high-magnification camera mechanism 50 (S8: high-magnification re-imaging step). Then, the image data re-imaged in the high-magnification re-imaging step (S8) is transferred to the screen display processing unit 62, subjected to predetermined preprocessing, and the image data re-imaged in the high-magnification re-imaging step (S8) is displayed as the high-magnification image HI instead of the high-magnification image HI captured in the high-magnification imaging step (S3) (S9: re-display step).

[0058] After that, when the display position of the high-magnification image HI is changed again by the operator's operation, the processes of S6 to S9 are repeatedly executed. On the other hand, when the display position of the high-magnification image HI is not changed by the operator's operation (NO in S5), the simultaneous display of the low-magnification image LI and the high-magnification image HI is continued. Also, when the operator performs, for example, an operation to hide the high-magnification image HI, an operation to enlarge or reduce the low-magnification image LI and the high-magnification image HI, and an operation to display the machining support image data, etc., the screen display process corresponding thereto is appropriately executed. Then, when a series of grinding processes, workpiece shape measurements, teachings, etc. are completed, the power is turned off by the operator, and a series of processes of the projection image display method are completed.

[0059] [Advantages of the digital projector according to the present embodiment] As described above, the digital projector 30 according to the present embodiment includes a main light source 32 (light source) such as an LED that irradiates the workpiece W (workpiece) with a light beam BM (light), a low-magnification camera mechanism 40 that captures a projection image of the workpiece W generated by the irradiation from the main light source 32, a beam splitter 36 provided on the optical path of the projection image, and a high-magnification camera mechanism 50 that captures the projection image of the workpiece W split by the beam splitter 36 in a range narrower than that of the low-magnification camera mechanism 40 and at a higher magnification than that of the low-magnification camera mechanism 40, and a display 31 that displays the low-magnification image LI captured by the low-magnification camera mechanism 40 and the high-magnification image HI captured by the high-magnification camera mechanism 50.

[0060] According to the digital projector 30 having such a configuration, while observing a wide range (for example, the whole) of the projection image obtained by enlarging the workpiece W and / or the grindstone 22 at a low magnification by the low-magnification image LI captured by the low-magnification camera mechanism 40, it is possible to perform observation of the workpiece details and shape dimension measurement by enlarging and displaying a more pinpoint range in the projection image of the workpiece W at a high magnification by the high-magnification image HI captured by the high-magnification camera mechanism 50.

[0061] In particular, in the digital projector 30 according to the present embodiment, by separately acquiring a low-magnification image LI and a high-magnification image HI by two sets of camera mechanisms, namely a low-magnification camera mechanism 40 and a high-magnification camera mechanism 50, it is possible to display the high-magnification image HI with high resolution, and thus it is possible to perform highly accurate measurement in micron units. Further, in the digital projector 30 according to the present embodiment, while grasping the overall shape of the workpiece W by the low-magnification image LI, a part of the workpiece W can be magnified and observed by the high-magnification image HI, so that even a non-expert can easily judge the shape and dimensions of the workpiece. Furthermore, in the digital projector 30 according to the present embodiment, since the low-magnification image LI and the high-magnification image HI are displayed on the display 31, it is possible to realize a grinding machine having high-functional added values such as image measurement and machining support.

[0062] Also, as described above, the digital projector 30 according to the present embodiment includes a high-magnification imaging lens 54 that magnifies the projection image at a predetermined magnification, a high-magnification camera 52 that captures the magnified projection image, and a high-magnification camera movement mechanism 57 that changes the imaging position of the high-magnification camera 52 with respect to the projection image. According to such a digital projector 30, since it is possible to change the imaging position of the high-magnification image HI on the projection image, it is possible to display an arbitrary position of the projection image as the high-magnification image HI.

[0063] Furthermore, as described above, the digital projector 30 according to the present embodiment is configured to be able to change the display position of the high-magnification image HI on the display 31, and the high-magnification camera movement mechanism 57 is configured to change the imaging position of the high-magnification camera 52 in accordance with the change in the display position of the high-magnification image HI. According to such a digital projector 30, by an intuitive operation of changing the display position of the high-magnification image HI on the display 31, it is possible to change the imaging position of the high-magnification camera 52, and thus the operability can be improved.

[0064] Also, as described above, the digital projector 30 according to the present embodiment is configured such that an intermediate focus is formed on the optical path between the work W (workpiece) and the low-magnification camera mechanism 40 and / or the high-magnification camera mechanism 50. The low-magnification camera mechanism 40 is configured to image the projection image that has passed through or been reflected (transmitted in the above example) by the beam splitter 36 and is split. The high-magnification camera mechanism 50 is configured to image the projection image that has been reflected or transmitted (reflected in the above example) by the beam splitter 36 and is split. According to such a digital projector 30, the working distance above the work W can be increased by the relay lens 33, and the optical configuration on the upstream side of the beam splitter 36 can be shared by the low-magnification camera mechanism 40 and the high-magnification camera mechanism 50. Therefore, it is possible to suppress the equipment cost, and the low-magnification camera mechanism 40 and the high-magnification camera mechanism 50 can simultaneously observe the same region (the same projection image before being split by the beam splitter 36) at different magnifications more reliably.

[0065] Furthermore, as described above, the digital projector 30 according to the present embodiment is configured to be able to display the low-magnification image LI and the high-magnification image HI overlapping on the display 31. According to such a digital projector 30, there is an advantage that it is easier to visually understand the position of the high-magnification image HI on the low-magnification image LI compared to the case where the low-magnification image LI and the high-magnification image HI are displayed at separate locations. Such an advantage is particularly prominent when the high-magnification image HI showing the shape (high-magnification projection image) of a part is superimposed and displayed on a part of the low-magnification projection image shown by the low-magnification image LI.

[0066] [Modification Example] As described above, the preferred embodiments of the present invention have been described, but the technical scope of the present invention is not limited to the scope described in the above embodiments. Various changes or improvements can be made to the above embodiments.

[0067] For example, in the above-described embodiment, the high-magnification camera mechanism 50 has been described as including the high-magnification imaging lens 54, the high-magnification camera 52, and the high-magnification camera moving mechanism 57. However, the present invention is not limited thereto, and a configuration without the high-magnification camera moving mechanism 57 may be employed.

[0068] In the above-described embodiment, it has been described that the imaging position of the high-magnification camera 52 is changed in accordance with the change in the display position of the high-magnification image HI on the display 31. However, the present invention is not limited thereto, and the high-magnification camera moving mechanism 57 may be operated by a jog operation or the like to change the imaging position of the high-magnification camera 52. Further, in this case, the display position of the high-magnification image HI on the display 31 may be changed in accordance with the change in the imaging position of the high-magnification camera 52.

[0069] In the above-described embodiment, it has been described that the low-magnification camera mechanism 40 captures one of the projected images that are transmitted and split by the beam splitter 36 and the projected images that are reflected and split, and the high-magnification camera mechanism 50 captures the other projected image. However, the present invention is not limited thereto, and various configurations can be adopted as long as the projected image can be captured by the high-magnification camera mechanism 50 in a range narrower than that of the low-magnification camera mechanism 40 and at a higher magnification. For example, an optical configuration for transmitting the projected image of the workpiece W (workpiece to be processed) to the low-magnification camera mechanism 40 and an optical configuration for transmitting the projected image of the workpiece W (workpiece to be processed) to the high-magnification camera mechanism 50 may be provided independently of each other.

[0070] In the above-described embodiment, it has been described that the low-magnification image LI and the high-magnification image HI are displayed on the display 31 in an overlapping manner. However, the present invention is not limited thereto. For example, as shown in FIG. 7, the low-magnification image LI and the high-magnification image HI may be arranged side by side without overlapping, or the low-magnification image LI and the high-magnification image HI may be displayed on different displays. In these cases, for example, as shown in FIG. 7, a guide frame line G indicating which part of the low-magnification projected image of the low-magnification image LI the part indicated by the high-magnification image HI is may be displayed.

[0071] In the above-described embodiment, the machine tool has been described as the copying grinding machine 1, but the present invention is not limited thereto, and it can be used for various machine tools as long as it is a machine tool equipped with a digital projector.

[0072] It is apparent from the description of the claims that such a modification as described above is included in the scope of the present invention.

Explanation of Reference Numerals

[0073] 1: Copying grinding machine 10: Work holding mechanism 20: Grinding wheel holding mechanism 22: Grinding wheel 30: Digital projector 31: Display 32: Main light source 33: Relay lens 34: Beam splitter for reflected image 35: Reflecting mirror 36: Beam splitter 37: Light source for reflected image 40: Low-power camera mechanism 42: Low-power camera 44: Low-power imaging lens 50: High-power camera mechanism 52: High-power camera 54: High-power imaging lens 56: Reflecting mirror 57: High-power camera moving mechanism 58: Movable housing 59x: X-axis direction drive unit 59y: Y-axis direction drive unit 60: Projector control unit 62: Screen display processing unit 64: Drive processing unit 66: Storage unit 70: Operation control panel BM, BM´: Light rays G: Guide frame line HI: High-power image LI: Low-power image W: Work

Claims

1. A light source that irradiates the workpiece with light, A low-magnification camera mechanism that images the projected image of the workpiece generated by the irradiation from the light source, A beam splitter provided on the optical path of the projected image, A high-magnification camera mechanism that images the projected image split by the beam splitter in a range narrower than that of the low-magnification camera mechanism and at a higher magnification than the low-magnification camera mechanism, A display that displays the low-magnification image captured by the low-magnification camera mechanism and the high-magnification image captured by the high-magnification camera mechanism and comprising, The high-magnification camera mechanism A high-magnification imaging lens that magnifies the projected image to a predetermined magnification, A high-magnification camera that images the magnified projected image, A high-magnification camera movement mechanism that changes the imaging position of the high-magnification camera with respect to the projected image including, A digital projector.

2. The display position of the high-magnification image on the display is configured to be changeable, The high-magnification camera movement mechanism is configured to change the imaging position of the high-magnification camera in response to the change in the display position of the high-magnification image The digital projector according to Claim 1.

3. An intermediate focus is configured to be formed on the optical path between the workpiece and the low-magnification camera mechanism and / or the high-magnification camera mechanism, The low-magnification camera mechanism is configured to image either the projected image transmitted through and split by the beam splitter or the projected image reflected and split by the beam splitter, The high-magnification camera mechanism is configured to image the other projected image of the projected image reflected and split by the beam splitter and the projected image transmitted and split by the beam splitter The digital projector according to Claim 1 or 2.

4. The digital projector according to any one of Claims 1 to 3, wherein the low-magnification image and the high-magnification image can be displayed overlapping on the display.

5. A machine tool comprising the digital projector according to any one of Claims 1 to 4.

6. A method for displaying a projected image using the digital projector according to any one of Claims 1 to 4, A light irradiation step of irradiating the workpiece with light, A low-magnification imaging step of imaging the projected image of the workpiece generated by the light irradiation step with the low-magnification camera mechanism, A high-magnification imaging step of imaging the projected image split by the beam splitter with the high-magnification camera mechanism in a range narrower than that of the low-magnification camera mechanism and at a higher magnification than the low-magnification camera mechanism A display step of displaying the low-magnification image captured by the low-magnification imaging step and the high-magnification image captured by the high-magnification imaging step on the display An image projection display method including the above steps.

Images