Machining system, tool management method

Abstract

To provide a machining system and a tool management method that can accurately detect the state of a machined surface even when halation occurs.SOLUTION: A machining system comprising: a machine tool that machines a workpiece using a turning tool having a cutting insert that machines the workpiece; a camera that can photograph a machined surface of the workpiece; a lighting device that illuminates the machined surface photographed by the camera; and a management device that manages the cutting inserts based on an image of the machined surface photographed by the camera. Therein the management device includes: an image processing unit that converts the image of the machined surface into grayscale; a halation detection unit that detects halation areas included in the image on the basis of brightness of each pixel that constitutes the image of the machined surface; and a determination unit that determines a state of the machined surface in a determination target area that excludes the halation areas from an entire area of the machined surface.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a machining system and a tool management method. [Background technology]

[0002] Patent Document 1 discloses a cutting tool including a tool body with a cutting blade that performs cutting on a workpiece, and an imaging device that photographs the machined surface of the workpiece that has been cut by the cutting blade. In such a cutting tool, the imaging device photographs the machined surface of the workpiece, allowing the wear state of the cutting blade to be ascertained, and the cutting blade to be replaced as necessary. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Patent Publication No. 2021-154417 Summary of the Invention [Problem to be solved by the invention]

[0004] In the configuration disclosed in Patent Document 1, in order to grasp the wear state of the cutting blade based on a photographed image of the machining surface, changes in the state of the machining surface caused by the degree of wear of the cutting blade are detected by image processing. For example, as the wear of the cutting blade progresses, the machining surface may become cloudy. Therefore, the wear state of the cutting blade can be grasped by determining whether the ratio of the cloudy portion of the machining surface to the entire machining surface in the photographed image of the machining surface is equal to or greater than a preset threshold.

[0005] Incidentally, when photographing the machined surface of a workpiece with an imaging device, illumination light may be irradiated onto the machined surface. When illumination light is irradiated onto the machined surface, halation, also known as whiteout, may occur in the image photographed by the imaging device. If halation occurs in a part of the image, it may be difficult to distinguish it from the cloudy part that has appeared on the machined surface, and the state of the machined surface may not be accurately detected by image processing.

[0006] In view of the above circumstances, an object of the present invention is to provide a machining system and a tool management method that can accurately detect the state of a machined surface even when halation occurs. [Means for solving the problem]

[0007] One aspect of the machining system of the present invention comprises a machine tool that processes a workpiece using a turning tool having a cutting insert for machining the workpiece, a camera that can photograph the machined surface of the workpiece, a lighting device that illuminates the machined surface photographed by the camera, and a management device that manages the cutting insert based on the image of the machined surface photographed by the camera, wherein the management device includes an image processing unit that grayscales the image of the machined surface, a halation detection unit that detects halation areas included in the image based on the brightness of each pixel that constitutes the image of the machined surface, and a judgment unit that judges the state of the machined surface in a judgment target area that excludes the halation areas from the entire area of ​​the machined surface.

[0008] According to one aspect of the processing system of the present invention, the state of the processing surface is determined by excluding the halation area from the entire area of ​​the processing surface photographed by the camera. As a result, even if halation occurs, the influence of halation can be eliminated and the state of the processing surface can be detected with high accuracy.

[0009] In the machining system, the determination unit may determine the state of the machined surface based on a ratio of the pixels in the determination target region whose luminance is equal to or greater than a predetermined reference value.

[0010] In this case, the condition of the machined surface is judged based on the proportion of pixels whose brightness is equal to or greater than a preset reference value in a judgment area, which is the entire area of ​​the machined surface excluding the halation area, so that it is possible to detect an increase in cloudiness on the machined surface due to wear of the cutting insert. Therefore, it is possible to appropriately determine the timing of replacing the cutting insert based on the condition of the machined surface.

[0011] In the above-mentioned processing system, the judgment unit may output information regarding the state of the cutting insert when the proportion of pixels in the judgment target area whose brightness is equal to or greater than a predetermined reference value is equal to or greater than a predetermined threshold value.

[0012] In this case, if the cloudiness on the machined surface increases due to wear of the cutting insert, information regarding the condition of the cutting insert is output, allowing the user of the machining system to replace the cutting insert at the appropriate time.

[0013] In the above-described machining system, the turning tool may have a tool body having a base on which a cutting insert for machining a workpiece can be attached, and the camera and the lighting device may be provided on the tool body.

[0014] In this case, in a machining system using a turning tool equipped with a camera and a lighting device on the tool body, the state of the machined surface can be detected with high accuracy even if halation occurs.

[0015] One aspect of the tool management method of the present invention is a tool management method for a machining system including a machine tool that processes a workpiece using a turning tool having a cutting insert that processes the workpiece, a camera that can photograph the machined surface of the workpiece, and an illumination device that illuminates the machined surface photographed by the camera, the method including the steps of grayscaling the image of the machined surface photographed by the camera, detecting a halation area included in the image based on the brightness of each pixel that constitutes the image of the machined surface, and excluding the halation area from the entire area of ​​the machined surface to determine the state of the machined surface.

[0016] According to one aspect of the tool management method of the present invention, the state of the machined surface is determined by excluding the halation area from the entire area of ​​the machined surface photographed by the camera. Therefore, even if halation occurs, the influence of halation can be excluded and the state of the machined surface can be detected with high accuracy. [Effects of the Invention]

[0017] According to the machining system and tool management method of one aspect of the present invention, even if halation occurs, the state of the machined surface can be detected with high accuracy. [Brief explanation of the drawings]

[0018] [Figure 1] 1 is a diagram showing a processing system according to an embodiment of the present invention; [Figure 2] FIG. 2 is a side view of a turning tool in the machining system of one embodiment of the present invention. [Figure 3] FIG. 2 is a perspective view of a head portion of a turning tool in the machining system of one embodiment of the present invention. [Figure 4] FIG. 2 is a functional block diagram of a management device in the machining system according to an embodiment of the present invention. [Figure 5] 1 shows an example of an image of a machining surface captured by a camera in a machining system according to an embodiment of the present invention. [Figure 6] FIG. 6 is a diagram showing an example of the distribution of luminance for each pixel constituting an image, obtained by grayscaling the image of FIG. 5. [Figure 7] FIG. 6 is a diagram showing an example of a halation region in the image of FIG. 5. [Figure 8] FIG. 10 is a graph showing the relationship between the number of workpieces cut with the cutting insert and the change in cloudiness rate. [Figure 9] FIG. 10 is a diagram showing an example of a machined surface of a workpiece machined with a worn cutting insert. [Figure 10] 1 is a flowchart showing the flow of a tool management method according to an embodiment of the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0019] Hereinafter, a turning tool 1 according to an embodiment of the present invention will be described with reference to the drawings. In the following drawings, the scale and number of each structure may differ from the actual structure in order to make each component easier to understand.

[0020] <Turning tool unit> Fig. 1 is a diagram showing a machining system 10 according to an embodiment of the present invention. Fig. 2 is a side view of a turning tool 1. Fig. 3 is a perspective view of a head portion 22 of the turning tool 1. As shown in FIG. 1, the machining system 10 includes a turning tool 1, a machine tool 9, and a management device 100.

[0021] The turning tool 1 of this embodiment performs turning, such as boring, on a workpiece W, such as a metal material, that is rotated around a spindle of a machine tool 9. As shown in FIG. 2 , the turning tool 1 of this embodiment is made of metal and includes a tool body 2, a cutting insert 4, and a head unit 7.

[0022] The tool body 2 extends in an axial direction Dj along the tool axis J. The tool body 2 has a cylindrical shank portion 21 centered on the tool axis J, and a head portion 22 provided on one side Dj1 of the shank portion 21 in the axial direction Dj of the tool body 2.

[0023] As shown in Figures 2 and 3, the head portion 22 has a protrusion 23 that protrudes from the outer peripheral surface of the shank portion 21 outward in a radial direction Dr of the tool body 2 that intersects with the axial direction Dj. A base 23d is provided on the protrusion 23. An insert attachment 41 is attached to the base 23d. The insert attachment 41 holds a cutting insert 4. The cutting insert 4 is arranged on a first side Dr1 of the tool body 2 in the radial direction Dr with respect to the tool axis J.

[0024] The cutting insert 4 has a diamond shape when viewed in the thickness direction. The cutting insert 4 has a pair of diamond-shaped main surfaces in a plan view facing the thickness direction and side surfaces connecting the pair of main surfaces. A cutting edge 42 is provided on the ridge between the main surfaces and the side surfaces of the cutting insert 4. The cutting edge 42 is provided at the tip portion of one side Dj1 in the axial direction Dj of the tool body 2. A portion of the cutting edge 42 protrudes from the tool body 2 to the one side Dj1 in the axial direction Dj. In addition, the cutting edge 42 protrudes outward in the radial direction Dr of the tool body 2. Therefore, a portion of the cutting edge 42 is located at the forefront of the one side Dj1 in the axial direction Dj of the tool body 2 and at the outermost end in the radial direction Dr.

[0025] According to this embodiment, the cutting insert 4 is fixed to the tool body 2 via the insert attachment 41. Therefore, by changing the insert attachment 41, cutting inserts 4 of various shapes can be fixed to the tool body 2, thereby increasing the versatility of the tool body 2.

[0026] The head unit 7 is provided in the head part 22. As shown in FIG. The head unit 7 is disposed on the second side Dr2 of the tool body 2 in the radial direction Dr with respect to the tool axis J. That is, the head unit 7 is disposed on the opposite side of the tool axis J from the base 23d and the cutting insert 4 attached to the base 23d in the radial direction Dr of the tool body 2.

[0027] The holder member 70 is detachably attached to the tool body 2. The sensor device 3 includes a first distance sensor 31 and a second distance sensor 32. In this embodiment, the first distance sensor 31 and the second distance sensor 32 measure the distance to the machined surface of the workpiece W machined using the cutting insert 4. In this embodiment, the first distance sensor 31 and the second distance sensor 32 are eddy current sensors. The first distance sensor 31 and the second distance sensor 32 are provided on a holder member 70.

[0028] The first distance sensor 31 and the second distance sensor 32 have their respective tip surfaces 31a and 32a facing the object to be measured. The first distance sensor 31 and the second distance sensor 32 generate a high-frequency magnetic field by passing a high-frequency current through them. This causes eddy currents to flow on the surface (machined surface) of the object to be measured, which is a conductor, and changes the impedance of the coils inside the first distance sensor 31 and the second distance sensor 32. The first distance sensor 31 and the second distance sensor 32 detect the distance to the machined surface, which is the object to be measured, from this change in impedance. Eddy current sensors tend to maintain stable measurement accuracy despite disturbances such as those in the surrounding environment. Therefore, eddy current sensors are more suitable for distance measurement in a disturbance-prone environment after cutting, regardless of whether wet or dry cutting is selected, compared to optical distance sensors, for example.

[0029] A tip surface 31a of the first distance sensor 31 is arranged facing outward in the radial direction Dr from the outer peripheral surface of the tool body 2. The first distance sensor 31 measures the distance to a measurement object arranged outside the radial direction Dr of the tool body 2. That is, the measurement direction of the first distance sensor 31 is the outside of the radial direction Dr. The first distance sensor 31 measures the distance to a machined surface machined by the cutting insert 4 facing inward in the radial direction Dr.

[0030] The tip surface 32a of the second distance sensor 32 is arranged facing one side Dj1 in the axial direction Dj from the tip 22s of the head portion 22 of the tool body 2. The second distance sensor 32 measures the distance to a measurement object arranged on the one side Dj1 in the axial direction Dj of the tool body 2. That is, the second distance sensor 32 uses the one side Dj1 in the axial direction Dj as its measurement direction. The second distance sensor 32 measures the distance to a machined surface machined by the cutting insert 4 and facing the other side Dj2 in the axial direction Dj.

[0031] The camera 5 is provided in the holder member 70 of the tool body 2. The camera 5 is disposed on the other side Dj2 in the axial direction Dj with respect to the sensor device 3, with the tool axis J interposed therebetween. For example, it is a waterproof CMOS image sensor or CCD image sensor. The camera 5 is provided facing the object to be photographed. The camera 5 is disposed facing outward in the radial direction Dr.

[0032] A camera opening 76 is formed in the holder member 70. The camera 5 provided in the holder member 70 is arranged so as to be able to photograph the outside in the radial direction Dr of the tool body 2 through the camera opening 76. The camera 5 photographs the machined surface of the workpiece machined by the cutting insert 4, which faces inward in the radial direction Dr, that is, the so-called inner diameter surface.

[0033] The camera 5 is disposed on the other side Dj2 in the axial direction Dj of the cutting insert 4 attached to the base 23d. However, it is preferable to dispose the camera 5 in a position as close as possible to the machining position of the machined surface by the cutting insert 4 in the axial direction Dj. This allows the state of the machined surface after machining to be photographed from a closer position. Also, for example, when the sensor device 3 is disposed in a position different from the above, the camera 5 may be disposed in the same position in the axial direction Dj with respect to the cutting insert 4. This allows the machined surface to be photographed from a closer position during or after cutting by the cutting insert 4.

[0034] The lighting device 6 is provided on the holder member 70. The lighting device 6 is arranged on the other side Dj2 in the axial direction Dj with respect to the camera 5. The lighting device 6 illuminates the machined surface to be photographed by the camera 5. As a result, the camera 5 is arranged between the first distance sensor 31 and the second distance sensor 32 of the sensor device 3 and the lighting device 6 in the axial direction Dj. The lighting device 6 includes a light source 61.

[0035] The light source 61 is a light-emitting element such as an LED. The light source 61 is fixed to a holder member 70. As shown in FIG. 3, an inclined portion 71k is formed in the holder member 70. The inclined portion 71k is formed on the other side Dj2 in the axial direction Dj with respect to the camera opening 76. The inclined portion 71k extends from the outer periphery of the camera opening 76 toward the other side Dj2 in the axial direction Dj, inclining toward a first side Dr1 in the radial direction Dr. As a result, a step surface 71d facing the one side Dj1 in the axial direction Dj is formed between the outer periphery of the holder member 70 and the tip of the inclined portion 71k on the other side Dj2 in the axial direction Dj. A light source opening 79 is formed in the step surface 71d, and a part of the light source 61 is exposed.

[0036] Illumination light from the light source 61 is irradiated to one side Dj1 in the axial direction Dj through the light source opening 79. The illumination light from the light source 61 is reflected by the surface of the inclined portion 71k and is irradiated onto the processing surface on the outer side in the radial direction Dr.

[0037] As shown in FIG. 2, the turning tool 1 includes a tool control unit 81 and a communication unit 82. In this embodiment, the tool control unit 81 is, in terms of hardware, a control board housed in the shank portion 21, for example. The tool control unit 81 is a computer equipped with a CPU (Central Processing Unit), a memory, etc. A control program for controlling the operations of the first distance sensor 31, the second distance sensor 32, the camera 5, and the light source 61 is stored in advance in the memory (not shown) of the tool control unit 81. The tool control unit 81 outputs control signals for controlling the operations of the first distance sensor 31, the second distance sensor 32, the camera 5, and the light source 61 to the first distance sensor 31, the second distance sensor 32, the camera 5, and the light source 61 based on a command from the management device 100. The tool control unit 81 outputs detection signals output in accordance with the detection results (distances) of the first distance sensor 31 and the second distance sensor 32 to the outside via the communication unit 82. The tool control unit 81 outputs image data captured by the camera 5 to the outside via the communication unit 82.

[0038] The communication unit 82 is capable of wireless communication with the outside. In terms of hardware, the communication unit 82 is a communication module mounted on a control board that constitutes the tool control unit 81. The communication unit 82 is capable of wireless communication with the management device 100 via a wireless communication network such as wireless LAN, Wi-Fi (registered trademark), or Bluetooth (registered trademark). The communication unit 82 receives control signals output from the management device 100 for controlling the operation of the first distance sensor 31, the second distance sensor 32, the camera 5, and the light source 61. The communication unit 82 transmits detection signals (output values) from the first distance sensor 31 and the second distance sensor 32, image data captured by the camera 5, and the like to the management device 100.

[0039] The tool control unit 81, the first distance sensor 31, the second distance sensor 32, the camera 5, and the light source 61 are supplied with power by a power supply module (not shown). The tool control unit 81, the communication unit 82, and the power supply module may be housed in a case, and this case may be attached to, for example, the tool body 2 itself or a holder that holds the tool body 2.

[0040] <Management device> FIG. 4 is a functional block diagram of the management device 100. The management device 100 is, for example, a computer device such as a personal computer, a tablet terminal, a smartphone, etc. In terms of hardware, the management device 100 includes a CPU (Central Processing Unit), a memory, a storage device, etc. When a workpiece is machined by the turning tool 1 based on a machining program stored in the machine tool 9, the management device 100 controls the operation of the first distance sensor 31, the second distance sensor 32, the camera 5, and the light source 61 of the turning tool 1 based on commands from the machine tool 9. The management device 100 measures the dimensions of the workpiece using the first distance sensor 31 and the second distance sensor 32 based on commands from the machine tool 9.

[0041] Furthermore, the management device 100 in this embodiment photographs the machined surface of the workpiece with the camera 5, and manages the cutting insert 4, which is a tool, based on the photographed image of the machined surface. Specifically, the management device 100 in this embodiment detects the condition of the machined surface based on the image of the machined surface photographed by the camera 5. The management device 100 estimates the wear state of the cutting insert 4 based on the detected state of the machined surface, and manages the replacement timing of the cutting insert 4 according to the estimated wear state of the cutting insert 4.

[0042] The management device 100 includes an acquisition unit 101, an image processing unit 103, a halation detection unit 105, a determination unit 107, and a display unit 109, which are implemented by a CPU executing a program stored in the device in advance.

[0043] FIG. 5 shows an example of an image of the processed surface captured by the camera 5. The acquisition unit 101 is capable of wireless communication with the communication unit 82 via wired communication by Ethernet (registered trademark) using a communication cable, or wireless communication by wireless LAN, Wi-Fi (registered trademark), Bluetooth (registered trademark), etc. The acquisition unit 101 acquires data of an image Im of the machined surface of the workpiece W output from the camera 5, as shown in FIG.

[0044] Fig. 6 is a diagram showing an example of the distribution of brightness for each pixel constituting the image Im, obtained by grayscaling the image Im in Fig. 5. The image processing unit 103 grayscales the image Im of the machining surface photographed by the camera 5, acquired by the acquisition unit 101, through appropriate image processing. As shown in Fig. 6, the image processing unit 103 classifies each pixel P constituting the image Im of the machining surface photographed by the camera 5 into, for example, 256 levels of brightness, from black (brightness 0) to white (brightness 255). That is, the image processing unit 103 stores each pixel P constituting the image Im in association with the brightness value of each pixel P.

[0045] FIG. 7 is a diagram showing an example of the halation region A1 in the image Im of FIG. The halation detection unit 105 detects a halation area A1 included in the image Im based on the luminance of each pixel P that constitutes the image Im of the processing surface. When the luminance of each pixel P that constitutes the image Im of the processing surface is equal to or greater than a preset halation reference value (for example, 250), the halation detection unit 105 determines that halation occurs in that pixel P. As a result, the halation detection unit 105 determines, as a halation area A1, pixels P with a luminance of 250 or greater within the entire area A of the image Im in which the processing surface is captured. In this way, the halation area A1 included in the image Im is detected, for example, as shown in FIG. 7.

[0046] The determination unit 107 excludes the halation region A1 from the entire region A of the processing surface, and sets the portion of the entire region A of the processing surface other than the halation region A1 as a determination target region A2. The determination unit 107 determines the state of the processing surface for the set determination target region A2. For example, the determination unit 107 detects the amount (proportion) of pixels P whose luminance is equal to or greater than a predetermined reference value in the set determination target region A2 as the state of the processing surface. For this purpose, the determination unit 107 identifies pixels P whose luminance is equal to or greater than a predetermined reference value in the determination target region A2. In this embodiment, the determination unit 107 calculates the proportion of pixels P whose luminance is equal to or greater than a predetermined reference value in the determination target region A2 to the number of pixels in the determination target region A2 (hereinafter, this will be referred to as the cloudiness ratio). The determination unit 107 determines the state of the processing surface based on the calculated cloudiness ratio. The determination unit 107 determines whether the cloudiness ratio is equal to or greater than a predetermined threshold. In this embodiment, for example, a control limit value (for example, 40%) and a cloudiness threshold value (for example, 35%) that is smaller than the control limit value are set as the threshold values.

[0047] Fig. 8 is a diagram showing the relationship between the number of workpieces W cut with the cutting insert 4 and the change in opacity rate. Fig. 9 is a diagram showing an example of the machined surface of a workpiece W machined with a worn cutting insert 4. Here, as shown in Fig. 8, the cloudiness rate on the machined surface tends to increase as the number of workpieces W cut with the cutting insert 4 increases. This is thought to be because, as the number of workpieces W cut with the cutting insert 4 increases, the cutting insert 4 wears, the cutting edge becomes uneven, and chips from the workpiece W cut by the cutting insert 4 adhere to the machined surface, causing the machined surface to become rough. When the machined surface of the workpiece W becomes rough, the illumination light from the lighting device 6 is diffused, as shown in Fig. 9, and the area of ​​high brightness (pixel P) increases.

[0048] When the calculated cloudiness rate is greater than the control limit, the determining unit 107 determines that the wear state of the cutting insert 4 has reached its usable limit. When the calculated cloudiness rate is greater than the cloudiness threshold and equal to or less than the control limit, the determining unit 107 determines that the wear state of the cutting insert 4 has not yet reached its usable limit but is approaching it. When the calculated cloudiness rate is equal to or less than the cloudiness threshold, the determining unit 107 determines that the wear state of the cutting insert 4 is usable.

[0049] When the calculated opacity rate is equal to or greater than a preset threshold, the determination unit 107 outputs information about the state of the cutting insert 4. When the calculated opacity rate is greater than the control limit, the determination unit 107 outputs, for example, information indicating that the wear state of the cutting insert 4 has reached its usable limit, as information about the state of the cutting insert 4. Specifically, in this case, the determination unit 107 outputs an instruction signal to display a message, turn on an alarm lamp, or the like, to request replacement of the cutting insert 4. In this case, the determination unit 107 may stop the machine tool 9 until replacement of the cutting insert 4 is completed. Furthermore, when the calculated cloudiness rate is greater than the cloudiness threshold value and equal to or less than the control limit value, the determination unit 107 outputs information indicating that the wear state of the cutting insert 4 is approaching its usable limit, as information regarding the state of the cutting insert 4. Specifically, in this case, the determination unit 107 outputs an instruction signal to display a message, turn on an alarm lamp, or the like, indicating that the time to replace the cutting insert 4 is approaching.

[0050] The display unit 109 displays information about the state of the cutting insert 4 based on the instruction signal output from the determination unit 107 .

[0051] <Tool management method> Next, a tool management method in the machining system 10 described above will be described. 10 is a flowchart showing the flow of a tool management method in the machining system 10 in this embodiment. In this embodiment, the tool management method in the machining system 10 is performed, for example, every time machining of a workpiece W is completed. The tool management method in the machining system 10 may also be performed at intervals, for example, every time machining of a predetermined number of workpieces W is completed. As shown in FIG. 10, the tool management method in the machining system 10 includes step S11 of acquiring an image, step S12 of grayscaling the image, step S13 of detecting a halation area, and step S14 of determining the state of the machined surface.

[0052] In step S11 of acquiring an image, an image of the machined surface of the workpiece W photographed by the camera 5 is acquired. In this embodiment, the management device 100 instructs the turning tool 1 to turn on the light source 61 of the lighting device 6 and to photograph the machined surface with the camera 5. Based on the instruction from the management device 100, the turning tool 1 turns on the light source 61 of the lighting device 6 to illuminate the machined surface and photographs the machined surface with the camera 5. The turning tool 1 transfers data of the image of the machined surface photographed by the camera 5 to the management device 100. After photographing the image, the turning tool 1 turns off the light source 61 and ends photographing by the camera 5. The acquisition unit 101 of the management device 100 acquires the image Im of the machined surface photographed by the camera 5 in this manner.

[0053] In step S12 of grayscaling the image, the image Im of the processing surface photographed by the camera 5, acquired in step S11, is grayscaled by the image processing unit 103. As shown in Fig. 6, the image processing unit 103 divides each pixel P constituting the image Im of the processing surface photographed by the camera 5 into, for example, 256 levels of brightness.

[0054] In step S13 of detecting a halation region, the halation detection unit 105 detects a halation region A1 included in the image Im based on the luminance of each pixel P that constitutes the image Im of the processing surface that has been grayscaled in step S13. When the luminance of each pixel P that constitutes the image Im of the processing surface is equal to or greater than a preset halation reference value (e.g., 250), the halation detection unit 105 determines that halation occurs in that pixel P. For example, as shown in Fig. 7, the halation detection unit 105 determines that, within the entire region A of the image Im, a pixel P whose luminance is equal to or greater than the halation reference value is a halation region A1.

[0055] In step S14 for determining the state of the machined surface, the state of the machined surface is determined by excluding the halation region A1 set in step S13 from the entire region A of the machined surface. Step S14 for determining the state of the machined surface includes step S141 for setting a region to be determined, step S142 for calculating a cloudiness rate, step S143 for determining whether the cloudiness rate is greater than a control limit value, step S144 for determining whether the cloudiness rate is greater than a cloudiness threshold value, step S145 for outputting information indicating that the cutting insert has reached its usable limit, and step S146 for outputting information indicating that the cutting insert is approaching its usable limit.

[0056] In step S141 for setting a determination target area, the determining unit 107 sets a determination target area A2 by excluding the halation area A1 from the entire area A of the processing surface.

[0057] In step S142 of calculating the cloudiness rate, the determination unit 107 calculates the cloudiness rate, which is the ratio of pixels P in the determination target area A2 whose luminance is equal to or greater than a preset reference value to the total number of pixels in the determination target area A2.

[0058] In step S143 for determining whether the cloudiness rate is greater than the control limit, the determination unit 107 determines whether the cloudiness rate calculated in step S142 is equal to or greater than the preset control limit. As a result, if the cloudiness rate is equal to or greater than the control limit (Yes in step S143), the determination unit 107 determines that the wear state of the cutting insert 4 has reached its usable limit. In this case, the process proceeds to step S145.

[0059] In step S145 of outputting information indicating that the cutting insert has reached its usable limit, if the cloudiness rate is greater than the control limit, the determination unit 107 outputs information regarding the state of the cutting insert 4, for example, information indicating that the wear state of the cutting insert 4 has reached its usable limit. The determination unit 107 outputs an instruction signal to display a message, turn on an alarm lamp, or the like, to prompt the user to replace the cutting insert 4. Based on the instruction signal output from the determination unit 107, the display unit 109 displays a message, turns on an alarm lamp, or the like, to prompt the user to replace the cutting insert 4. The determination unit 107 may stop the machine tool 9 until replacement of the cutting insert 4 is complete.

[0060] In step S143, if the cloudiness rate is not equal to or greater than the control limit value (No in step S143), the process proceeds to step S144. In step S144, which determines whether the cloudiness rate is greater than a cloudiness threshold, the process determines whether the cloudiness rate calculated in step S142 is greater than the cloudiness threshold. As a result, if the cloudiness rate is greater than the cloudiness threshold (Yes in step S144), the determination unit 107 determines that the wear state of the cutting insert 4 has not yet reached its usable limit but is approaching it. In this case, the process proceeds to step S146.

[0061] In step S146 of outputting information indicating that the cutting insert is approaching its usable limit, if the calculated opacity rate is greater than the opacity threshold, the determination unit 107 outputs information indicating that the wear state of the cutting insert 4 is approaching its usable limit as information regarding the state of the cutting insert 4. The determination unit 107 outputs an instruction signal to display a message, turn on an alarm lamp, or the like, indicating that it is approaching the time to replace the cutting insert 4. Based on the instruction signal output from the determination unit 107, the display unit 109 displays a message, turns on an alarm lamp, or the like, indicating that it is approaching the time to replace the cutting insert 4.

[0062] When a plurality of workpieces W are machined, the above-described series of machining control methods is carried out for each of the plurality of workpieces W.

[0063] [Effects of this embodiment] According to the machining system 10 and the tool management method of the present embodiment described above, the halation area A1 is excluded from the entire area A of the machined surface photographed by the camera 5, and the state of the machined surface is determined. As a result, even if halation occurs, the influence of halation can be excluded and the state of the machined surface can be detected with high accuracy. By detecting the state of the machined surface with high accuracy, the wear state of the cutting insert 4 can also be detected with high accuracy.

[0064] Furthermore, in this embodiment, the state of the machined surface is determined based on the proportion of pixels P whose brightness is equal to or greater than a preset reference value in a determination target area A2, which is obtained by excluding the halation area A1 from the entire area A of the machined surface, so that it is possible to detect an increase in cloudiness on the machined surface due to wear of the cutting insert 4. Therefore, the timing to replace the cutting insert 4 can be appropriately determined based on the state of the machined surface.

[0065] In addition, in this embodiment, when the cloudiness on the machining surface increases due to wear of the cutting insert 4, information regarding the condition of the cutting insert 4 is output, so that the user of the machining system 10 can replace the cutting insert 4 at the appropriate time.

[0066] Furthermore, in this embodiment, in the machining system 10 using the turning tool 1 equipped with the tool body 2, the camera 5, and the lighting device 6, the state of the machined surface can be detected with high accuracy even when halation occurs.

[0067] [Other configurations included in the present invention] The present invention is not limited to the above-described embodiment, and the configuration can be changed within the scope of the present invention, as will be described below.

[0068] In the above embodiment, the camera 5 and the lighting device 6 are provided on the tool body 2, but this is not limiting. The camera 5 and the lighting device 6 may be provided on the machine tool 9 side, for example.

[0069] In the above embodiment, the processing of the workpiece W, the turning on and off of the lighting device 6, the taking of pictures by the camera 5, etc. in the turning tool 1 are performed by the management device 100, but this is not limiting. The processing of the workpiece W, the turning on and off of the lighting device 6, the taking of pictures by the camera 5, etc. in the turning tool 1 may be configured to be controlled on the machine tool 9 side.

[0070] In the above-described embodiment, the opacity rate of the processed surface is obtained as the state of the processed surface, but this is not limited to this. Information other than the opacity rate of the processed surface may be obtained as the state of the processed surface based on the image Im captured by the camera 5. Furthermore, in the above-described embodiment, the timing of replacing the cutting insert 4 of the turning tool 1 is managed based on the condition of the machining surface, but this is not limited to this, and it is also possible to manage, for example, the machining quality of the workpiece W machined by the turning tool 1 based on the condition of the machining surface.

[0071] Furthermore, the configurations (elements) described in the above-described embodiments, modifications, and notes may be combined without departing from the spirit of the present invention, and additions, omissions, substitutions, and other modifications of the configurations are possible. Furthermore, the present invention is not limited to the above-described embodiments, but is limited only by the claims. [Explanation of symbols]

[0072] 1...Turning tool 2…Tool body 3...Sensor device 4...Cutting insert 5. Camera 6...Lighting equipment 7...Head unit 9…Machine tools 10...Processing system 21...Shank 22...Head 22s…Tip 23...Protruding part 23d…Pedestal 31...First distance sensor 31a, 32a...Tip surface 32...Second distance sensor 41...Insert attachment 42...Cutting edge 61...Light source 70...Holder member 71d…Step surface 71k…Slope part 76...Camera opening 79…Light source aperture 81...Tool control unit 82…Communications Department 100…Management device 101…Acquisition Department 103...Image processing unit 105...Halation detection unit 107...Judgment section 109...Display section A…Entire area A1...Halation area A2…Judgment target area Dj…Axis direction Dj1...one side Dj2...other side Dr…Radial direction Dr1…first side Dr2…Second side Im…Image J…Tool axis LAN...Wireless P...pixel S11, S12, S13, S14, S141, S142, S143, S144, S145, S146...Steps W…Work material

Claims

1. a machine tool that processes a workpiece using a turning tool having a cutting insert that processes the workpiece; a camera capable of photographing the processed surface of the workpiece; an illumination device that illuminates the processed surface photographed by the camera; a management device that manages the cutting insert based on the image of the machining surface captured by the camera, The management device an image processing unit that converts the image of the processed surface into grayscale; a halation detection unit that detects a halation region included in the image based on the brightness of each pixel that constitutes the image of the processed surface; a determination unit that determines the state of the processed surface in a determination target area excluding the halation area from the entire area of ​​the processed surface, Processing system.

2. the determination unit determines the state of the processed surface based on a ratio of the pixels in the determination target region whose luminance is equal to or greater than a predetermined reference value. The processing system of claim 1 .

3. the determination unit outputs information about the state of the cutting insert when a ratio of the pixels in the determination target region whose brightness is equal to or greater than a predetermined reference value is equal to or greater than a predetermined threshold value. The processing system according to claim 1 or 2.

4. The turning tool is a tool body having a base on which a cutting insert for machining a workpiece can be attached; The camera and the lighting device are provided on the tool body. The processing system of claim 1 .

5. a machine tool that processes a workpiece using a turning tool having a cutting insert that processes the workpiece; a camera capable of photographing the processed surface of the workpiece; a lighting device that illuminates the machining surface photographed by the camera, grayscaling the image of the processing surface captured by the camera; detecting a halation region included in the image based on the brightness of each pixel constituting the image of the processed surface; and excluding the halation area from the entire area of ​​the processed surface to determine the state of the processed surface. Tool management method.

Images