Collision inspection method for machining process using substitute workpiece

Abstract

1. A method for collision inspection of a machining process, comprising: A method in which a machining process is provided with a process-specific cycle during which a plurality of machining components (B) are moved relative to one another using at least one machine axis (A, X, Y, Z) on a machine tool (2), the machining components (B) including at least one workpiece (20) and a tool (7), the workpiece (20) rotating about a work axis (WSA) and the tool (7) rotating about a tool axis (WZA) during at least a portion of the process-specific cycle, The invention is characterized in that at least one inspection position is determined in a process-specific cycle, the inspection position corresponding to a relative position of the machining component (B) set with at least one machine axis (A, X, Y, Z), and the relative position of the machining component (B) is reproduced to check each inspection position for collisions, and in the reproduction, one or more substitute machining components (E) are used, which include a substitute workpiece (3) which is a copy or partial copy of the corresponding machining component (B) and a partial copy of the workpiece (20), in which the workpiece (20) is reproduced over at least an axial sub-area (17) and over only a part of the circumference of the workpiece (20), and in the reproduced relative position, the substitute workpiece (3) is rotated around the workpiece axis (WSA). The invention provides a simple, cost-effective and safe method for collision inspection of machining processes.

Description

[Technical field]

[0001] The present invention relates to a method for collision inspection of a machining process, A process-specific cycle is provided for the machining process, during which a number of machining components are moved relative to one another using at least one machine axis on the machine tool, the machining components including at least one workpiece and a tool, and during at least a portion of the process-specific cycle, the workpiece rotates about a work axis and the tool rotates about a tool axis. [Background technology]

[0002] Such a method is known from EP 2 306 253 B1.

[0003] In the manufacture of gears, transmissions and other workpieces, various machine tools are used in which a tool, in particular a toothed tool, rotating about a tool axis engages a workpiece, in particular a toothed tool, rotating about a workpiece axis. The tool and the workpiece on the machine tool, and possibly other machining components, must therefore be moved relative to one another in a suitable manner, in particular for infeed and feed. An example of such a machine tool can be found in Swiss patent No. 715794.

[0004] Within the scope of such machining processes, process-specific cycles are carried out, during which the participating machining components, including at least the workpiece and the tool, are moved relative to one another by at least one machine axis.

[0005] When a machining process is newly set up on a machine tool, the planned process-specific cycle must be checked for unintended collisions of machining components ("collision check"). For example, parts of the tool that are not used for machining or the tool holder of the tool must not come into contact with the workpiece or the clamping means of the workpiece during the process-specific cycle.

[0006] Collision inspection is often performed visually by means of the machine tool: the original machined component is assembled on the machine tool and, under the supervision and control of an operator, is carefully, usually stepwise, brought as close as possible to the desired position of the machined component, who then repeatedly observes the machined component and estimates whether an unintended collision will occur and, if necessary, stops the approach to the desired position.

[0007] This approach is often difficult. In many cases, the operator does not have a good view of the machining component during the collision check, even if the machine tool is switched off and the machine housing is repeatedly opened. The workpiece often hides other machining components, especially if the radial inside of the workpiece is to be machined. Sometimes the operator's visibility can be improved by optical aids such as mirrors or endoscopes, but there is often not enough space to use such aids. Another drawback is that during the collision check, the workpiece and the tool start to engage with each other, so that the operator often cannot approach the position of the machining component that should be examined at all. The operator then has to mentally add the remaining infeeds that have not yet been made or the feed that has not yet been made to the set position and then mentally estimate the collision situation. If the operator does not recognize the impending collision when gradually approaching the desired position, the original machining component may be damaged during the collision check, and especially the replacement of the tool in case of damage is often very expensive.

[0008] It is also known to perform collision checking geometrically / mathematically. This requires sufficiently accurate 3D data of all involved machining components. The 3D data and the planned process-specific cycles are entered into a specific software. The software checks whether undesirable collisions occur. However, the costs involved in providing and possibly updating the 3D data are very high, the software programming is complex or the corresponding software licenses are often expensive. An example of a mathematical collision checking is described in EP 2 306 253. Furthermore, from EP 2 849 014 A1 it is known to carry out a mathematical collision monitoring during the gear cutting process. [Prior art documents] [Patent documents]

[0009] [Patent Document 1] European Patent No. 2306253 [Patent Document 2] Swiss Patent No. 715794 Summary of the Invention [Problem to be solved by the invention]

[0010] It is an object of the present invention to provide a method for collision inspection of manufacturing processes that is simple, cost-effective and safe. [Means for solving the problem]

[0011] The object is achieved by a method of the type mentioned at the outset, which method comprises the steps of: determining, in a process-specific cycle, at least one inspection position which is checked for collisions with respect to the workpiece component; the inspection position corresponds to a relative position of the machined component defined by at least one machine axis; In order to check the respective inspection positions for collisions, the relative positions of the machining components are reproduced, and in the reproduction, one or more substitute machining components are used which are copies or partial copies of the corresponding machining components, the one or more substitute machining components including substitute workpieces which are partial copies of the workpiece, in which the workpiece is reproduced over at least an axial partial area and over only a part of the circumference of the workpiece, It is contemplated that in the recreated relative position, the substitute workpiece is rotated about the workpiece axis.

[0012] The invention contemplates reproducing particularly collision-prone relative positions of machined components ("test positions") identified in a process-specific cycle during a collision test, where one or more substitute machined components are used in place of the original machined component, including at least one substitute machined workpiece in place of the original workpiece.

[0013] By using the alternative machining components, on the one hand, it is possible to protect also parts that may collide with the corresponding original or alternative machining components during the collision test from damage. The alternative machining components are essentially manufactured from a cost-effective, flexible material (preferably elastic or easily plastically deformable material). In case of a collision during the collision test, only the alternative machining component or components are deformed, which is not damaging or at least not very damaging, and no damage occurs to other parts, e.g. the machine tool or the model of the machine tool. Typical materials for the alternative machining components are plastic, metal sheet (preferably with a plate thickness of about 2 mm, or with a plate thickness of 1 mm to 3 mm), or cardboard / cardboard.

[0014] On the other hand, the invention contemplates forming the substitute workpiece not as a complete copy of the original workpiece, but as a partial copy of the original workpiece, where the workpiece is copied only over a portion of its circumference by the substitute workpiece, at least in an axial partial region of the workpiece, in other words, in the copy, a portion of the circumference of the workpiece is omitted at least in an axial partial region, and in the copy, at least 1 / 3 of the circumference of the workpiece is omitted in the substitute workpiece (at least in an axial partial region).

[0015] This can essentially allow for a better view of the machined component and the alternative machined component for the operator, and makes it easier to recognize possible collisions. In particular in the case of internally toothed workpieces, it is possible with the alternative workpiece to see radially inward of the workpiece, which would not be possible with the original workpiece. However, by rotating the alternative workpiece (typically by the operator's hand), it remains possible to check for collisions with the alternative workpiece over the entire circumference of the workpiece (and in particular those parts of the circumference of the workpiece that are not replicated with the alternative workpiece).

[0016] Typically, the toothing of the workpiece is also replicated over only a portion of the circumference. In this case, the collision check allows the tool or substitute tool to simulate its full penetration and full feed by bringing the substitute workpiece into a rotational position in which it engages the non-replicated circumferential portion of the substitute workpiece. By rotating the substitute workpiece up to the tool or substitute tool, it can be easily estimated whether a collision nevertheless occurs. It should be noted that alternatively or additionally, the toothing of the workpiece can be replicated at least locally in the substitute workpiece by an envelope or surface that corresponds to the root circle of the toothing, which likewise allows the simulation of the full penetration and full feed. In general, the tool and the workpiece are rotationally symmetrical (the number of symmetries corresponds to the number of teeth in the toothing).

[0017] It may be envisaged to duplicate a workpiece over only a part of its circumference and over its entire axial extent with a substitute workpiece, thereby optimizing the operator's visibility, but it is also possible to limit the omission of a part of the circumference in the duplication to axial partial areas that are particularly important for good visibility.

[0018] It should be noted that in addition to the alternative workpiece, the further alternative machining component can also replicate the associated machining component at least over an axial partial area, over only a part of its circumference or over its entire circumference. Preferably, in addition to the workpiece, clamping means for the workpiece and / or tool are also replicated by the alternative machining component and are used when replicating the inspection position.

[0019] Typical machining components are (in addition to the workpiece and the tool) clamping means for the workpiece, a tool holder for the tool, workpiece-specific tooling (also called auxiliary tools, in particular one or more gas nozzles for blowing away the chips, one or more suction nozzles for sucking the chips, one or more KSS nozzles for supplying cooling lubricant (KSS), one or more centering sensors), a work spindle or a tool spindle.

[0020] In the case of three-dimensional alternatively machined components, these can be produced, for example, by 3D printing (usually from plastic), but essentially any production method is conceivable. Two-dimensional alternatively machined components ("templates") are preferably cut out of flat material (for example cardboard or metal sheet), for example by laser cutting or water jet cutting.

[0021] Typical inspection positions are the beginning or end of the engagement of the workpiece with the tool during machining, or the places of change of direction of the machining component, and the end points of the movement of the machining component. It should be noted that within the scope of the method according to the invention, the inspection positions can be approached manually, semi-automatically or even automatically.

[0022] The machine tool is typically a gear cutting machine, in particular a gear skiving machine, for example a hard gear skiving machine, or a gear grinding machine, for example a generating or profile grinding machine, or a honing machine or a gear hobbing machine. The machine axes used in the process-specific cycles can in particular be linear or rotary axes.

[0023] If the collision check results in no unintended collisions of machining components occurring in the intended process-specific cycle, the machining process can be started (with all original machining components) on the machine tool. If the collision check reveals unintended collisions between machining components, the intended process-specific cycle is modified to avoid the collisions. Typically, a collision check is then performed again on the modified process-specific cycle before the machining process is started.

[0024] Preferred variants of the invention In an advantageous variant of the method according to the invention, the reconstruction of the relative positions of the machining components is carried out on a model of the machine tool that is separate from the machine tool, so that a collision check (e.g. of the machining process to be set up next) can be carried out without interrupting production (by the previous machining process) on the machine tool. The machine axes of the machine tool, which are typically not motorized, are replicated in the model.

[0025] An alternative variant is preferred, in which the reproduction of the relative positions of the machining components is carried out on the machine tool. This avoids the need to prepare a model of the machine tool. Furthermore, the original machining component or the motorized machine axes present on the machine tool can be easily utilized for the collision test. Basically, all structures of the machine tool can be taken into account in the collision test, without any structures being forgotten. In this variant, the one or more substitute machining components are attached to the machine tool, preferably by means of magnets and / or screws and / or other fastening elements. The other (non-substitute) machining components are permanently present on the machine tool or are assembled in real life.

[0026] A development of this variant is preferred in which the machine tool has at least one workpiece spindle with at least one clamping means and the substitute workpiece is attached to the clamping means for reproduction. By utilizing the original clamping means on the workpiece spindle of the machine tool, the attachment of the substitute workpiece for collision testing is particularly simple. If the machine tool has several workpiece spindles, the substitute workpiece can be attached to one or several workpiece spindles, respectively, by means of the clamping means thereon.

[0027] A development of the above-mentioned variants is advantageous in which, for reproduction, the replacement workpiece is attached to an intermediate holder, which is attached directly or indirectly to the workpiece spindle, in particular by means of a clamping means of the workpiece spindle. The intermediate holder facilitates the attachment of the replacement workpiece to the original workpiece spindle. The replacement workpiece does not have to be attachable directly to the original clamping means or directly to the original workpiece spindle. The intermediate holder can be used as a fastening means between the replacement workpiece and the workpiece spindle or the clamping means, and can be adapted to the replacement workpiece on the one hand and to the workpiece spindle or the clamping means on the other hand. The intermediate holder can be designed to mount the replacement workpiece non-rotatably on the workpiece spindle (whereby the replacement workpiece is set so that it can only rotate via the workpiece spindle) or the intermediate holder can form its own rolling bearing (whereby the intermediate holder is used as a temporary rolling holder, see also below).

[0028] In a preferred development of the above variant, the substitute workpiece is mounted on a work spindle of a machine tool for reproduction, and the work spindle of the machine tool is rotated in order to rotate the substitute workpiece about its work axis. Utilizing the rotary bearings of the work spindle for rotating the substitute workpiece is particularly simple in construction. The rotation of the substitute workpiece on the work spindle can be performed manually or electrically (slowly, usually in steps).

[0029] In an advantageous variant, it is provided that the substitute workpiece is mounted on a temporary rotary holder for reproduction and that the substitute workpiece is rotated on the temporary rotary holder for rotation. This makes it unnecessary to use the workpiece spindle of the machine tool or its rotary bearings for rotating the substitute workpiece, which can be very laborious manually or very time-consuming in terms of programming and reliable execution electrically. The temporary rotary holder forms its own rotary bearing for rotating the substitute workpiece. The rotary bearing of the temporary rotary holder can be designed in particular as a sliding bearing or a rolling bearing. The temporary rotating holder comprises two mutually rotatable parts, a first of which holds the substitute workpiece directly or indirectly, and a second of which can be attached, for example, directly or indirectly to the original work spindle or original clamping means, or can also be attached to a corresponding structure of the model (in which case the second part is, for example, a sliding base or a rotating plate), or the second part is formed by a part of the outer contour of the original work spindle or original clamping means, on which part of the outer contour the first part can rotate and slide. In a sub-variant, a separate second part (for example a "ring" part) is formed at one end corresponding to the clamping contour of the workpiece and duplicated at the other end corresponding to a part of the outer contour of the work spindle, and the first part is designed to rotate and slide on this part of the outer contour of the work spindle, in which case the first part can selectively form the temporary rotating holder together with the separate second part (placed on the original clamping means) or with a part of the outer contour of the original work spindle as the second part. The temporary rotating holder is typically rotated manually and does not essentially belong to a machine tool. Needless to say, the rotation axis of the temporary rotating holder is aligned coaxially with the workpiece axis defined by the work spindle.

[0030] In a preferred embodiment, the replacement workpiece has an axial partial region in which the workpiece is replicated over only a portion of the circumference of the workpiece and an axial remainder region in which the workpiece is replicated over its entire circumference, in particular the portion of the circumference being provided with a plurality of part structures spaced apart from one another in the axial partial region. The remainder region allows the replacement workpiece to be attached, for example, to the original clamping means as a workpiece. The replacement workpiece is open over a portion of the circumference in the axial partial region, which allows for improved visibility for the operator, in particular in the case of internally toothed workpieces. Separate part structures, for example two part structures spaced apart by approximately 180° or three part structures spaced apart by approximately 120°, allow particularly good visibility. In some cases, the part structures can also be involved when clamping the replacement workpiece (for example by a jaw chuck or scroll chuck). The part structures extend in the circumferential direction over only a small angular range, usually less than 30°, in particular less than 20°.

[0031] Furthermore, variants are preferred in which the replacement workpiece replicates the workpiece at least in the axial partial area over at least 1 / 3 of its circumference and at most 2 / 3 of its circumference, in particular the partial workpiece is formed as a half workpiece. By using such partial workpieces, the collision situation can be particularly clearly indicated to the operator, who can grasp it particularly simply and quickly. Usually, only a small rotation of the replacement workpiece is required within the scope of the collision check. In the partial workpieces, the replicated parts of the circumference of the workpiece are typically continuous in the circumferential direction.

[0032] A variant in which the substitute workpiece fully or partially replicates only the cross-sectional contour of the workpiece is preferred, which makes the production of the substitute workpiece particularly easy, the cross-section being then taken in a plane containing the workpiece axis.

[0033] In a particularly preferred development of this variant, the substitute workpiece is formed by a two-dimensional template. The production of the two-dimensional template is particularly simple and cost-effective. Furthermore, a particularly good visibility is provided to the operator. The template can in particular be designed as a half template, which replicates (fully or partially) only half of the cross-sectional contour on one side of the workpiece axis. Similarly, the template can also be designed as a full template, which replicates (fully or partially) both halves of the cross-sectional contour on both sides of the workpiece axis. The template is typically attached to the machine tool (directly or indirectly to the workpiece spindle) or to a model of the machine tool by means of a template carrier.

[0034] In an advantageous sub-variant of this development, it is provided that the two-dimensional template is designed as a multi-template, which fully or partially reproduces the cross-sectional contours of different workpieces at different sections of its edge contour. This allows multiple workpieces to be easily and cost-effectively replicated with just one template and checked for collisions. By assembling the multi-template in a specific orientation, a specific section of the edge contour and thus a specific workpiece for collision inspection can be selected. A typical multi-template is formed with two to eight different sections, each of which corresponds to the cross-sectional contour of another workpiece.

[0035] To this end, a sub-variant of the above-mentioned development is advantageous, in which the two-dimensional template has mutually adjustable part segments, which are set to fully or partially copy the cross-sectional contour of the workpiece and / or the clamping means. Due to the adjustable part segments, the two-dimensional template can be universally used for virtually any workpiece and possibly also for clamping means, whose respective cross-sectional contours are adjusted with the adjustable part segments. Typically, the part segments have a diameter or maximum edge length in a cross section perpendicular to their extension of 2 mm or less, or often 1 mm or less.

[0036] Furthermore, a development of the above variant is advantageous, in which the substitute workpiece fully or partially replicates the cross-sectional contour of the workpiece and / or the clamping means by means of a light beam, in particular a laser beam. The light beam eliminates the risk of damage that may occur during the collision check. Furthermore, the light beam allows the operator to recognize the collision particularly easily in many cases. Usually, a set of light sources (e.g. laser diodes in the magnet holder) allows multiple cross-sectional contours of different workpieces and possibly also of the clamping means to be replicated without problems, so that the procedure can be widely used. The light beams have a wavelength or a wavelength spectrum in the visible spectral range, and the light beams are preferably selected with an intensity that is harmless to the human eye. Typically, at least three light beams are used simultaneously (e.g. at least two light beams in the horizontal direction and at least one light beam in the vertical direction). Alternatively, the cross-sectional contour can be partially replicated by means of rods, cords or wires instead of light beams. Alternatively, the substitute workpiece can also be produced by holography.

[0037] A sub-variant of this development is preferred, in which the light beams replicate the edges of the cross-sectional contour of the workpiece and / or the clamping means and / or the intersections of the light beams replicate the corner points in the cross-sectional contour of the workpiece and / or the clamping means. For example, a horizontal light beam can replicate the top edge of the workpiece and the bottom of a blind hole in the clamping means, and one or more vertical light beams can reproduce the inner diameter of the workpiece or the clamping means. This procedure has in practice proven to be effective for finding collisions. If a single positional relationship of the available light sources does not allow all relevant edges and corner points of the cross-sectional contour to be checked for collisions, multiple positions of the light sources for each (test) relative position can be built in sequence and checked for collisions.

[0038] In a preferred variant, the one or more substitute machining components comprise a substitute tool, which is a copy or partial copy of the tool. Damage to the original tool by the collision test can thereby be completely eliminated. Furthermore, in some cases, the original tool can be used for other purposes during the collision test or does not have to be manufactured yet for the collision test. The substitute tool can be produced, for example, by 3D printing. By 3D printing, even complex tools can be reproduced with relatively little effort (especially if the teeth of the tool are to be reproduced completely). The substitute tool can also be produced by methods other than 3D printing, for example by turning and / or milling. Typically, the teeth of the tool are omitted in the (partial) reproduction or are replaced by an envelope line or an envelope surface.

[0039] A development of this variant is preferred, which provides that the substitute tool is a partial copy of the tool, in which the tool is copied over only a part of the tool circumference, at least over an axial part area, and that in the copied relative position the substitute tool is rotated about its tool axis. This also improves the operator's visibility of the collision situation. By rotating the substitute tool, the part of the tool circumference that was not copied to the substitute tool can also be checked for collisions. The partial copy of the tool can be realized in particular by means of a two-dimensional template, as can the partial copy of the workpiece.

[0040] Also preferred is a development in which the one or more alternative machining components comprise an alternative tool holder which is a copy or a partial copy of a tool holder for holding a tool in a tool spindle of a machine tool, whereby the tool holder is also completely protected from damage during the collision test and possibly the operator's visibility can also be improved with respect to the tool holder.

[0041] Also advantageous is a variant in which the one or more alternative machining components include alternative clamping means that are a copy or partial copy of the clamping means for holding the workpiece on the work spindle of the machine tool. This makes it possible to eliminate or minimize damage to or by the clamping means during collision inspection. In some cases, the operator's visibility can also be improved with respect to the clamping means.

[0042] In a preferred development of this variant, the alternative clamping means is rotated together with the alternative workpiece in the reproduced relative position, in particular the alternative clamping means and the alternative workpiece being formed by a common two-dimensional template. This is particularly easy to set up: the alternative clamping means can be assembled, for example, on a temporary rotating holder or on a workpiece spindle.

[0043] Particularly preferred are variants which provide for the toothing of the corresponding machined component to be fully or partially replaced by an envelope or surface of the toothing in one or more alternative machined components. This significantly simplifies the manufacture of the alternative machined components. The envelope or surface can in particular extend along the tip or root circle of the toothing. By replicating the tip circle, it is possible to check for collisions of the toothing with (typically non-toothed) structures of other machined components. By replicating the root circle, it is possible to ensure that the mutual engagement of the two toothings does not prevent the reproduction of the relevant inspection position.

[0044] Furthermore, a variant in which the machining component includes at least one auxiliary tool, in particular the at least one auxiliary tool includes a gas nozzle assembly and / or a suction nozzle assembly and / or a cooling lubricant nozzle assembly and / or a centering sensor, is advantageous. The auxiliary tool or tools can also be called supplementary tooling. The at least one auxiliary tool is used to assist the tool in directly machining the workpiece before or during machining, and the auxiliary tool itself is typically not used to directly machine the workpiece. When reconstructing the relative position of the machining component, typically the original auxiliary tool of the machine tool is used, but it is also possible to use an alternative auxiliary tool. By taking the auxiliary tool into account in the collision inspection, unintended collisions involving the auxiliary tool can also be found, and thus possibly damage can be prevented.

[0045] A development of this variant is preferred, which provides for a function optimization of at least one auxiliary tool to take place in the reproduced relative position for at least one inspection position, in particular by positioning, alignment and / or selection of the auxiliary tool. By only partially duplicating the workpiece by an alternative workpiece and possibly the machining component by an alternative machining component, the auxiliary tool can be easily seen and accessed, so that an optimization of the auxiliary tool, in particular its positioning and alignment, can be particularly easily performed in the scope of the collision inspection. For example, a blow nozzle can be particularly precisely aimed at the location where chips are generated or where chips may accumulate.

[0046] Particularly preferred is the variant in which the workpiece partially replicated by the substitute workpiece is an internally toothed workpiece. With internally toothed workpieces, it is particularly difficult to visually check for collisions in the past, since the workpiece practically completely conceals the toothing to be machined and other structures located on the inside. When a partial replica of a workpiece is used as a substitute workpiece according to the invention, the visibility of the workpiece can be significantly improved, since the substitute workpiece is open over at least a part of the circumference of the workpiece. The invention is therefore particularly useful for internally toothed workpieces. Alternatively, the invention can also be used, for example, for externally toothed or spur toothed workpieces. In general, the workpieces to be inspected for collisions within the scope of the invention can have one or more toothings.

[0047] Furthermore, a variant is preferred in which at least one light gap is observed for collision checking when rotating the substitute workpiece. At least one of the light gaps can extend between the substitute workpiece and the tool or substitute tool. If the light gap disappears or falls below a certain size, a collision is recognized. Alternatively, a collision can be recognized on the basis of an increase in the rotation resistance or on the basis of a deflection, in particular of the substitute workpiece and / or the tool or substitute tool.

[0048] Furthermore, a variant is preferred in which at least one alternative machining component has a first and a second replica section, which replicate two similarly formed sections of the corresponding machining component, the type of replication being different between the first and the second replica section, in particular in that the similar section of the machining component carries one toothing, the first replica section replicating the tip circle of the toothing and the second replica section replicating the root circle of the toothing. Different types of replication may consist in particular in replicating the maximum radial and / or axial extension of the (circumferentially periodic) structure of the similar section in one of the replicas, and in another of the replicas this structure replicating the minimum radial and / or axial extension of the (circumferentially periodic) structure. This variant makes it possible both to directly find, for example, the collision of a toothing (in particular by the first replica section) and to reproduce the fully infeed / infested relative position, in which, for example, a toothing engages with another toothing of another machining component. Similar sections of the machined components can be transferred to one another by rotating (eg, about a workpiece axis in the case of an alternating workpiece).

[0049] Furthermore, it is advantageous in a variant in which at least one boundary marking is provided on at least one alternative machining component, indicating the boundaries of the structures of the associated machining component that are not or not completely replicated on the alternative machining component. The boundary marking can, for example, indicate the beginning and end of the teeth that are not or not completely replicated at least locally on the alternative machining component. The boundary marking allows the operator to more easily recognize collisions in the areas of the structures that are not or not completely replicated. The structures that are not or not completely replicated can allow adjustment of the fully infeed and / or fully fed relative positions of the alternative machining component and the machining component that would not be adjustable with a fully replicated structure.

[0050] In an advantageous variant, at least one alternative machining component is provided with an identification marking, which allows the identification of the alternative machining component and / or the allocation of the alternative machining component to the corresponding machining component, in particular the identification marking is human-readable and / or machine-readable, in particular the identification marking comprises an alphanumeric code and / or a QR code and / or a bar code and / or an RFID tag. This simplifies the handling of the machine tool and its alternative machining components and the execution of the method according to the invention, in particular in an automated flow. The identification marking can be, for example, printed, glued or engraved.

[0051] The scope of the present invention also includes a machine tool system designed to carry out the above-mentioned method according to the invention, which comprises a machine tool for machining at least one workpiece and one or more alternative machining components, which are respectively copies or partial copies of the corresponding machining components of the machine tool, including an alternative workpiece which is a partial copy of the workpiece, in which the workpiece is duplicated at least over an axial partial area and only over a part of the circumference of the workpiece. With the machine tool system according to the present invention, a collision check can be carried out simply, cost-effectively and safely, in particular by applying the above-mentioned method according to the present invention. The machine tool system can also include (besides the alternative workpiece) one or more other alternative machining components, for example an alternative tool, or an alternative clamping means, or an alternative tool holder. In addition to one or more machining components, the machine tool system can include both original and alternative machining components (e.g. original clamping means for a workpiece and associated alternative clamping means).

[0052] In a preferred embodiment of the machine tool system according to the invention, the machine tool comprises an electronic machine control device which is programmed to approach all identified inspection positions related to the inspection relative positions of alternative machining components and / or machining components arranged on the machine tool in order to carry out the above-mentioned method according to the invention, in particular it is provided that the inspection relative positions are the same as the relative positions of the machining components in the process-specific cycle or the inspection relative positions correspond to the relative positions of the machining components in the process-specific cycle plus an offset, the offset resulting from the mounting of each alternative machining component on the machine tool differently from the mounting of the corresponding original machining component. Thus, the implementation of the collision inspection method according to the invention is possible particularly simply and comfortably on the machine tool.

[0053] Furthermore, the scope of the invention also includes the use of a substitute machining component in the above-mentioned method according to the invention or in the above-mentioned machine tool system according to the invention, the substitute machining component being a copy or a partial copy of a corresponding machining component, in particular a substitute workpiece for a corresponding workpiece, in which the workpiece is copied at least over an axial partial area and only over a part of the circumference of the workpiece, by means of which a collision check is possible in a simple, cost-effective and safe manner.

[0054] Other advantages of the present invention will become apparent from the following description and drawings. The illustrated and described embodiments should not be construed as an exhaustive enumeration, but rather have an exemplary nature for explaining the present invention. [Brief description of the drawings]

[0055] [Figure 1] 2 shows a schematic side view of an exemplary embodiment of a machine tool system according to the invention for carrying out a method according to the invention for collision inspection, with an alternative workpiece designed as a semi-workpiece installed thereon; [Diagram 2] 1 in the region of the alternative workpiece. [Diagram 3]FIG. 2 shows a schematic perspective view of the half workpiece of FIG. 1; [Figure 4] 1 shows a schematic perspective view of an exemplary alternative workpiece of the present invention formed of three circumferentially spaced apart substructures; FIG. [Diagram 5] FIG. 6 is a schematic perspective view of the original workpiece of the alternative workpiece of FIGS. 4 and 5; [Figure 6] FIG. 2 is a schematic perspective view of the clamping means of FIG. 1 in isolation, with an alternative workpiece assembled thereto; [Figure 7] 2 shows a schematic perspective view of an alternative tool holder in isolation, assembled with the alternative tool of FIG. 1, in which the teeth of the original tool are replicated by an envelope surface; FIG. [Figure 8a] 1 shows a schematic perspective view of an exemplary replacement tool holder of the present invention having a replacement tool in which the teeth of the original tool are perfectly replicated; FIG. [Figure 8b] FIG. 2 shows a schematic perspective view of an exemplary alternative tool holder with an alternative tool designed as a two-dimensional template of the present invention. [Figure 9] 1 shows a schematic perspective view of another exemplary embodiment of a machine tool system according to the invention for carrying out a method according to the invention for collision inspection, with a two-dimensional template formed of an alternative workpiece and an alternative clamping means assembled thereon; [Figure 10] 10 shows an enlarged view of a region of the two-dimensional template of FIG. 9. [Figure 11] FIG. 10 shows an enlarged side view of the two-dimensional template of FIG. [Figure 12] FIG. 2 is a schematic perspective view of a template holder of an intermediate holder to which a multiple template is assembled, as viewed obliquely from above, according to the present invention. [Figure 13] FIG. 13 is a schematic perspective view of the template holder and the multiple template of FIG. 12 viewed obliquely from below. [Figure 14a] 1 shows a schematic perspective view from obliquely above of an exemplary intermediate holder designed as a temporary rotating holder with a plain bearing according to the invention; [Figure 14b] 14b shows a schematic perspective view of the intermediate holder of FIG. 14a seen obliquely from below. [Figure 14c]1 shows a schematic cross-sectional view of an exemplary intermediate holder designed as a temporary rotating holder with rolling bearings according to the invention; [Figure 15] 1 shows a schematic cross-sectional view of an alternative workpiece of the present invention designed as a two-dimensional template with adjustable partial segments. [Figure 16] FIG. 2 shows a schematic perspective view of a portion of another exemplary embodiment of a machine tool system according to the present invention for carrying out a collision inspection method according to the present invention using a substitute workpiece that partially replicates an original workpiece by means of a light beam; [Figure 17] 5 shows a schematic perspective view of a model replicating the machine axes of a machine tool for carrying out another variant of the collision inspection method according to the invention; DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0056] Fig. 1 shows a schematic side view of an exemplary embodiment of a machine tool system 1 according to the invention for carrying out an exemplary variant of the collision inspection method according to the invention. The machine tool system 1 comprises a machine tool 2 with an alternative workpiece 3 assembled thereon. Fig. 2 shows an enlarged portion of Fig. 1 in the region of the alternative workpiece 3. It should be noted that Fig. 9 shows another similar embodiment of the machine tool system 1, the general statements regarding the machine tool 2 being equally applicable to both embodiments. Fig. 10 shows an enlarged portion of Fig. 9 in the region of the alternative workpiece 3 therein, and Fig. 11 shows another enlarged side view of the alternative workpiece 3 of Fig. 9.

[0057] A machining process is planned on the machine tool 2, during which a workpiece (not shown in Figs. 1 / 2 and 9 / 10 / 11, but see Fig. 5, reference number 20) mounted on the machine tool 2 is to be machined, for example hard gear skiving, with a tool (not shown in Figs. 1 / 2, but see alternative tool 14 shown in Fig. 7 and tool with reference number 7 in Fig. 10). The workpiece then rotates about the work axis WSA (C-axis of the machine tool 2) of the work spindle 4 and the tool rotates about the tool axis WZA (B-axis of the machine tool) of the tool spindle 5, so that the workpiece and the tool are brought into engagement with each other. Typically, multiple workpieces are to be machined sequentially, whereby first a workpiece is mounted on the machine tool, machined and removed, then the next workpiece is mounted, machined and removed, etc.

[0058] In the course of machining the individual workpieces, the machining components B are moved relative to one another on the machine tool 2 by machine axes in a process-specific cycle. The process-specific cycle is repeated each time a new workpiece is machined. In that case, the machining components B of the machine tool 2 are at least a workpiece and a tool. The machine tool 2 is exemplarily shown here with the following machine axes which can be actuated within the process-specific cycle: a machine axis Y, by means of which the work slide 8 carrying the work spindle 4 can be displaced, here horizontally, relative to the machine bed 2b of the machine tool 2, a machine axis X, by which the tool slide 9 carrying the tool spindle 5 can be displaced, here horizontally, relative to the cross slide 10, a machine axis Z, by means of which the cross slide 10 carrying the tool slide 9 can be moved, here vertically relative to the machine bed 2b, - the machine axis A, around which the tool spindle 5 can swivel on the tool slide 9, which here extends horizontally (i.e. parallel to X).

[0059] The machine axes X, Y, Z are here mutually orthogonal. The machine tool 2 can be designed and in particular have a machine axis design as described in Swiss Patent No. 715794, the entire content of which is incorporated by reference into the present disclosure.

[0060] The workpiece has been selected in the illustrated example as an internally toothed workpiece, as can be seen from alternative workpiece 3 (see also FIG. 5 in this regard). Within the scope of a process-specific cycle, for example, steps S1 to S7 can be provided in the operating sequence of the machine axes X, Y, Z as follows (it is assumed in that the workpiece is initially in the workpiece change position and the tool is initially in a position for tool change in which the tool is displaced in the X and Z directions from the basic position), i.e. - S1: Move the work slide 8 along Y to carry the work from the work exchange position to the processing position; - S2: Move the tool slide 9 along the X axis and the cross slide 10 along the Z axis to bring the tool to its basic position; - S3: The cross slide 10 is moved downwards in the Z direction from the basic position of the tool, so that the tool performs machining on the workpiece (feed); - S4: Adjusting the tool slide 9 in X and, if necessary, in relation to the Y movement of the work slide 8 to disengage the workpiece from the tool; - S5: Move the cross slide 10 upward in Z direction to remove the tool from the workpiece; S6: moving the tool slide 9 over X and, if this has not been done in step S4, the cross slide 10 over Z until the tool is again in position for a workpiece change; - S7: The work slide 8 is moved along Y, and the work is again transported to the work exchange position.

[0061] Between steps S7 and S1, a workpiece exchange can be carried out, for example a workpiece exchange robot not shown in detail can be used for this purpose. At least between steps S3 and S4, the tool and the workpiece are rotated (B-axis and C-axis actuation, but these are generally not relevant for collision checking). In the above example, the machine axes X, Y, Z are mainly or consistently actuated individually in sequence, which is often preferred, but it is also possible to actuate several machine axes X, Y, Z at least temporarily simultaneously. It is also to be noted that the machine axes actuated in the cyclic process do not have to be linear axes, but can in particular also include pivoting axes. Furthermore, the machine axes can include redundant axes.

[0062] When planning a process-specific cycle, it is necessary to check (before the process-specific cycle is executed for the first time in the scope of actual workpiece machining) whether there are any unintended collisions between the machining components involved in the planned cycle ("collision check"). If "yes", machining can start. If no, the previously planned process-specific cycle needs to be modified. The invention therefore contemplates the following procedure for collision check:

[0063] First, one or more inspection positions are identified (determined) in the planned process-specific cycle. This identification can be performed by an electronic control unit that knows the planned process-specific cycle. The inspection positions then each represent a relative position (including orientation) of the machining components involved in the machining process, i.e. they correspond to a point in time in the process-specific cycle. The inspection positions are essentially defined (especially in their selection and number) in such a way that if there are no collisions at all planned inspection positions, then there will be no collisions for the entire process-specific cycle.

[0064] In many cases, the time points in the process-specific cycle where the operation of a machine axis ends and / or the operation of the next machine axis starts ("turn around") are well suited as inspection positions. If necessary, these inspection positions can be supplemented with further inspection positions, for example when two machining components are located in relative positions where maximum approach of the two machining components is expected (for example when the two machining components or protruding parts from them are "at the same height" in the direction of the machine axes). In the above example, for example inspection positions can be defined at the end of steps S2 to S4, respectively.

[0065] The relative positions of the involved machining components are then reproduced for each proposed inspection position. In that case, within the scope of the present invention, one or more original machining components B are replaced with an alternative machining component E, which is a copy or partial copy of the relevant original machining component B, and at least the workpiece is replaced with an alternative workpiece 3. The alternative workpiece 3 only copies the workpiece over a part of its circumference (at least in an axial partial area), i.e. a part of the circumference is omitted. This allows the operator a better view of the collision situation, in particular the radially inward direction of the alternative workpiece 3. Nevertheless, by rotating the alternative workpiece 3, the entire circumference of the alternative workpiece 3 or the workpiece can be inspected for collisions. In particular, the replicated part of the circumference can be brought to the collision risk position when rotating, without the rotational position belonging to the collision risk position having to be known or set in advance.

[0066] The machine tool 2 shown in Fig. 1 / Fig. 2 is provided with a workpiece, a clamping means 11 for the workpiece, a tool, a tool holder for the tool (see reference number 12 in Fig. 9 / Fig. 10 / Fig. 11), a gas nozzle assembly 13 and a centering sensor 28 as machining components B in the machining process. Parts of the machining components B are replaced with alternative machining components E for collision testing, and in the machine tool system 1 used for collision testing according to the present invention, in the embodiment of Fig. 1 / Fig. 2, the workpiece is replaced with an alternative workpiece 3, the tool with an alternative tool 14 and the tool holder with an alternative tool holder 15. The alternative machining components E are generally made of a cost-effective, flexible material, so that in the event of a collision during collision testing, the (original) machining components B involved in the collision are not damaged by the alternative components E.

[0067] In the embodiment shown in Fig. 1, the alternative machining component E is attached to the machine tool 2 in the same way as the corresponding original machining component B here, and therefore the relative position assigned to the inspection position is approached as an inspection relative position directly with the machine tool 2. The electronic machine control device 2a is programmed to step through the inspection relative positions one after the other, typically allowing the operator to manually move to the next inspection relative position. The machine tool 2 stops at each inspection relative position and the operator, typically with his bare hands, rotates the alternative workpiece 3, in Fig. 1 by the workpiece spindle 4 about the workpiece axis WSA in order to check for collision positions. When the inspection relative position has been checked, the operator closes the machine cover again and the next inspection relative position can be approached, and so on.

[0068] In the embodiment shown in FIG. 1 / FIG. 2, a gas nozzle assembly 13 and a centering sensor 28 are also provided as machining components B, which are here mounted on the housing of the tool spindle 5. The gas nozzle assembly 13 and the centering sensor 28 are examples of auxiliary tools 27 which are themselves not directly involved in the machining but which assist in the machining of the workpiece. The gas nozzle assembly 13 allows chips to be blown away from the engagement area of ​​the workpiece and the tool during machining. Within the scope of the collision check according to the invention, the gas nozzle assembly 13 is checked on the one hand for collisions (in particular for collisions with the workpiece / substitute workpiece 3 or its clamping means 11). On the other hand, the positioning and orientation of the gas nozzle assembly 13 (in particular the three associated gas outlet openings in the illustrated example) can be optimized, for example for the inspection position at the end of steps S2 and / or S3 and / or S4 in the above example. By only partially duplicating the workpiece by the substitute workpiece 3, this optimization is particularly easily possible for the operator, both with regard to accessibility and visibility of the gas nozzle assembly 13 and its parts. The centering sensor 28 detects the rotational position of the tool relative to the tool axis WZA to establish synchronization between the tool and the workpiece.

[0069] The alternative workpiece 3 used in the embodiment of Fig. 1 is shown in isolation in Fig. 3. The alternative workpiece 3 is designed as a partial workpiece 16a and here as a half-workpiece 16. In the illustrated half-workpiece 16, the associated original workpiece (see Fig. 5) is reproduced in succession over half the circumference (i.e. a circumferential angle of 180°), the remainder of the circumference being omitted in the reproduction. The alternative workpiece 3 in Fig. 3 reproduces the original workpiece over its entire axial height.

[0070] To check for collisions, the workpiece half 16 was allowed to rotate 180 degrees or more about the workpiece WSA so that the entire 360 ​​degree circular angular range was occupied by the workpiece half 16 at least once.

[0071] FIG. 4 shows an alternative embodiment of the alternative workpiece 3, in which the original alternative workpiece is replicated in the (here upper) axial partial region 17 over a portion of its circumference, i.e. by means of only three partial structures 19 divided in the circumferential direction. These partial structures 19 are here designed identically (alternatively it is also possible for the partial structure 19 to be provided with two or more replicated sections which replicate similar sections of the workpiece in different ways, not shown, but see FIG. 11 for this). The partial structures 19 are spaced apart from one another by approximately 120°. The circumferential regions between the partial structures 19 are omitted in the scope of the replication in the alternative workpiece 3 (as far as they belong to the (here lower) axial partial region 17). The original workpiece is replicated over the entire circumference in the (here lower) axial remaining region 18, which allows for an easy mounting of the alternative workpiece 3 on the clamping means.

[0072] To check for collisions, the alternative workpiece 3 could be rotated about the workpiece axis WSA by more than 120°, so that the entire circumferential angular range of 360° was occupied by the substructure 19 at least once.

[0073] Figure 5 shows, for comparison, an original workpiece 20 which is partly replicated by the alternative workpiece of figures 3 and 4. It has a toothing 21, i.e. an internal toothing 22.

[0074] In the alternative workpieces 3 of Figures 3 and 4, the toothing 21 has been replaced by an envelope surface 23 which here replicates the tip circle of the toothing 21. This makes it easier to produce the alternative workpieces 3. Otherwise, the dimensions of the respective alternative workpiece 3 correspond to those of the original workpiece 20. It should be noted that in the illustrated example the toothing 21 has a step 73, which can also be seen in the alternative workpiece (see reference number 3 in Figures 3 and 4).

[0075] Figure 6 shows in isolation the alternative workpiece 3 of Figure 4, mounted in a clamping means 11. The clamping means 11 can be attached to a workpiece spindle.

[0076] FIG. 7 shows in isolation the replacement tool 14 of FIG. 1 / FIG. 2 mounted in a replacement tool holder 15. The replacement tool holder 15 is provided with magnets 26, which facilitate mounting to the tool spindle. In the replacement tool 14, the teeth of the original tool have been replaced by an envelope surface 24. It should be noted that the replacement tool 14 is now replicated over its entire circumference. The replacement tool 14 can be manufactured, for example, by a turning operation.

[0077] Figure 8a shows an alternative embodiment of a replacement tool 14 and a replacement tool holder 15 similar to the embodiment of Figure 7. However, here, the toothing of the original tool is also fully (i.e. every toothing) replicated in the replacement tool 14 by toothing 25. The replacement tool 14 can be made from plastic, for example by 3D printing.

[0078] FIG. 8b shows another alternative embodiment of a substitute tool 14 and a substitute tool holder 15 similar to the design of FIG. 7. Here, however, the substitute tool 14 is formed by a two-dimensional template 74 and thus replicates the original tool only for a part of its circumference, i.e. the area of ​​the cross section (including the tool axis). The teeth of the original tool are replaced on the substitute tool 14 by an envelope 75 corresponding to the cross-sectional contour on the tip circle of the teeth. The substitute tool 14 can be cut out, for example, from a metal sheet. The substitute tool 14 designed as a two-dimensional template 74 can be inserted, for example, in a slot on the underside of the substitute tool holder 15 (not shown in detail). For the collision test, the substitute tool 14 is rotated around the tool axis, here by a rotation bearing of the tool spindle.

[0079] Fig. 9 shows a schematic perspective view of another exemplary embodiment of a machine tool system 1 according to the invention for carrying out the method for collision checking according to the invention in another exemplary variant. Fig. 10 shows an enlargement of Fig. 9 in the region of a substitute workpiece 3, here designed as a two-dimensional template 30, and Fig. 11 shows an additional enlargement from the side of the two-dimensional template 30. The machine tool system 1 has already been largely described above in Fig. 1 / Fig. 2, so that only the main differences thereto will be described here.

[0080] 9 / 10 / 11, in a machine tool system 1 used for collision testing according to the invention, the workpiece and the clamping means for the workpiece are replaced by an alternative workpiece 3 and an alternative clamping means 29. The alternative workpiece 3 and the alternative clamping means 29 are then formed together by a two-dimensional template 30, which partially replicates in its upper part 34 the contour of the workpiece and in its lower part 35 the contour of the clamping means. The tool 7 with the teeth 7a and the tool holder 12 are here the original machining components B. It should be noted that if desired, the tool 7 and the tool holder 12 can also be replaced by alternative machining components instead (not shown in detail here, but see Figs. 7, 8a, 8b for this).

[0081] The two-dimensional template 30 only replicates the cross-sectional contour of the workpiece and the clamping means (the part relevant for the collision test). It is very simple and cost-effective to produce, for example by punching or cutting out a plastic sheet, a cardboard plate or sheet metal. On the other hand, it allows a very good visualization of the collision situation. The two-dimensional template 30 here is a full template which replicates the cross-sectional contour of the workpiece on both sides of the workpiece axis WSA.

[0082] The two-dimensional template 30 is here provided with an RFID tag 31 and an alphanumeric code (characters) 32 which is recognizable to the naked eye. The RFID tag 31 and the alphanumeric code 32 are examples of identification markings 33 which allow easy identification of the template 30 and in particular easy assignment to the original tool and to the original clamping means.

[0083] As can be particularly seen from FIG. 11, the cross-sectional contour of the workpiece is replicated in different ways on both sides (halves) of the two-dimensional template 30. On the left side of FIG. 11, in a first replicated section 36, a part of the toothing of the workpiece is replicated by an envelope 38 corresponding to the tip circle of the toothing. On the right side of FIG. 11, in a second replicated section 37, another part of the toothing of the workpiece is replicated (over the maximum, here lower, part of the axial extension of the tooth) by an envelope 39 corresponding to the root circle of the toothing. The aforementioned and the other part of the workpiece are designed similarly (i.e. they can be transferred to each other by rotating the workpiece by 180° here). The first replicated section 36 allows to check collisions with the machining component or an alternative machining component in an inspection position where engagement with the toothing of the workpiece is not intended. The second replicated section 37 allows to bring the workpiece 7 with its toothing 7a (or in another embodiment an alternative tool) close to the root circle of the toothing of the alternative workpiece, i.e. to simulate a complete engagement with the toothing of the workpiece. By rotating the template 30 through (approximately) 360°, the collisions can be examined all around.

[0084] The two-dimensional template 30 has boundary markings 40 in the area of ​​the second replicated section 37 that indicate where the not fully replicated teeth end in the area of ​​the second replicated section 37. This makes it easier for the operator to verify the inspection relative position and to recognize possible collisions when the operator subsequently uses the second replicated section.

[0085] Also clearly visible in Fig. 11 is a typical light gap 72 that an operator can look for to find a collision. In Fig. 11, the depicted light gap 72 is located between the tool holder 12 and the (radially inner) contour of the substitute workpiece 3. In the illustrated relative position of machining component B and substitute machining component E, no collision occurs because a sufficient light gap 72 still remains between the substitute workpiece 3 and the tool holder 12. If the substitute workpiece 3 or the 2D template 30 were to be rotated and the substitute workpiece 3 and the tool holder 12 were to come into contact (i.e., the light gap 72 would disappear), a collision would exist.

[0086] The two-dimensional template 30 is here mounted on an intermediate holder 76, which is also arranged on the original clamping means 11 of the machine tool 2. The original clamping means 11 is assembled on the work spindle 4. It should be noted that the original clamping means 11 is not used here for the collision check, but the alternative clamping means 29, which is formed together with the two-dimensional template 30. The clamping means 11 is used here only to support (mount) the intermediate holder 76. The intermediate holder 76 here comprises the template carrier 42 and a lower part 77 (largely obscured in FIG. 10 ) to which the template carrier 42 is fixed non-rotatably by fastening elements 48, in particular knurled screws 49. The two-dimensional template 30 is fixed on the template carrier 42, and the lower part 77 is fixed on the (original) clamping means 11. To rotate the alternative workpiece 3, the alternative workpiece 3 together with the intermediate holder 76 and the clamping means 11 is rotated by the work spindle 4 or by a rotary bearing. However, it should be noted that by omitting the knurled screw 49, the intermediate holder 76 can also be used as a temporary rotary holder with its own rotary bearing designed as a plain bearing (see in this respect Figures 14a / 14b).

[0087] However, due to this structure, the positions (in the Z direction) of the alternative workpiece 3 and the alternative clamping means 29 (or the template 30) during collision inspection do not match the positions of the workpiece and the original clamping means 11 during the actual workpiece machining. The alternative workpiece 3 and the alternative clamping means 29 are positioned "too high" by an offset 43 from the original position.

[0088] In the embodiment shown in Fig. 9 / Fig. 10 / Fig. 11, an inspection relative position with the machine tool 2 is approached that corresponds to the relative position assigned to the inspection position plus this offset 43. The offset 43 compensates for the fact that the alternative workpiece 3 and the alternative clamping means 29 are not attached to the machine tool 2 in the same way as the corresponding original machining component B here. The machine control device 2a is programmed to sequentially approach the thus adapted inspection relative positions. It should be noted that the offset 43 of the alternative workpiece 3 can be indicated by a character 32 or can be stored in the RFID tag 31, so that the operator can enter this offset into the machine control device, or the machine control device can automatically read and receive the value of the offset 43.

[0089] Figure 12 is a perspective view from diagonally above, and Figure 13 is a perspective view from diagonally below, which again explain the structure of the template carrier 42 of the intermediate holder 76 of Figures 9 / 10 / 11, but unlike these figures, here a multiple template 44 designed as a half template 45 is held in the template carrier 42.

[0090] The template carrier 42 is formed with a base plate 46, which is formed with a recess in the form of a positioning prism 47 on the inside (towards the work axis WSA). Fastening elements 48 are arranged on the base plate 46 for attaching the template carrier 42, for example, to the lower part of an intermediate holder (see reference number 77 in FIG. 10) or to a rotating dish of a temporary rotating holder (see reference number 58 in FIG. 14c) or possibly directly to another structure, such as a clamping means or a work spindle. A knurled screw 49 and a magnet 50 are shown here by way of example as fastening elements 48. The base plate 46 here comprises a cover plate 46a (typically made of metal) and a plastic prism 46b located thereunder.

[0091] Furthermore, the template carrier 42 here has two tabs 51 to which one or more two-dimensional templates 30 can be attached, again using knurled screws 52 as fastening elements 53 for the template or templates 30. As shown, the tabs 51 can be metal sheet sections bent up from the cover plate 46a, or can be additional structures attached to the base plate 46 (the latter not shown in detail).

[0092] In the illustrated form, the two-dimensional template 30 mounted on the template carrier 42 is selected as the multi-template 44. Here, the multi-template 44 is designed as a double template (2-fach-Schablone) with two different sections 55, 56 of its edge contour, each of which replicates the cross-sectional contour of the other workpiece. Depending on the orientation in which the multi-template 44 is assembled on the template carrier 42, the multi-template 44 serves as a substitute workpiece 3 for one or the other workpiece. In the illustrated orientation of the multi-template 44, the section 56 is used for the collision check, by which the cross-sectional contour of the internally toothed workpiece is partially replicated on the upper part 34. On the lower part 35, the section 56 also partially replicates the clamping means, so that the multi-template 44 simultaneously serves as a substitute clamping means 29. If the template 30 of FIG. 12 is assembled on the template carrier 42 in an orientation rotated 180° around the vertical axis, the section 55 will be used for the collision check.

[0093] Since the multi-template 44 replicates the cross-section of each workpiece on only one side (the left side in FIG. 12), the multi-template 44 is referred to as a half-template 45. This allows a particularly good visualization of the collision situation.

[0094] Figures 14a and 14b show perspective views of a variant of the intermediate holder of Figures 9 / 10 / 11. In the variant of Figures 14a / 14b, an intermediate holder 76 can be used as a temporary rotating holder 41. The template carrier 42 and the lower part 77 are designed to a large extent as described in Figures 9 / 10 / 11 and 12 / 13, and only the main differences will be described.

[0095] The temporary rotary holder 41 comprises here a template carrier 42 and a lower part 77. However, the template carrier 42 is not here fixed non-rotatably to the lower part 77, but is merely abutted against a receiving part 79 of the lower part 77 by means of a positioning prism 47. The receiving part 79 forms an annular projection relative to a flat sliding surface 78a on the upper surface of the lower part 77, on which the template carrier 42 rests with its plastic prism 46b. The plastic prism 46b can also be called a sliding element. Furthermore, in this version, the lower part 77 can also be called the sliding base 78 of the temporary rotary holder 41 or simply a ring based on its overall structure.

[0096] While the positioning prism 47 rests against the receiving portion 79 and thereby centers the template carrier 42, the template carrier 42 can be rotated, optionally by hand, about the workpiece axis WSA (which runs through the center of the receiving portion 79), the template carrier 42 (or the plastic prism) sliding with its lower surface on the sliding surface 78a. In that case, it is not necessary to operate the workpiece spindle in order to rotate the substitute workpiece 3.

[0097] The lower part 77 has an annular projection 78b on its lower surface, by means of which the lower part 77 can be attached, for example, to a primary clamping means. The lower part 77 can in particular be made of steel.

[0098] Figure 14c shows, by way of example, in cross section, the main parts of an alternative intermediate holder 76 of the invention which can also be utilized as a temporary rotating holder 41 and which can be used, for example, in place of the intermediate holder therein in the machine tool system embodiments of Figures 9 / 10 / 11.

[0099] The temporary rotating holder 41 has a foot part 57, which can typically be mounted on a primary clamping means (not shown here, but see for example FIG. 10, reference number 11 there). A rotating dish 58 is supported on the foot part 57 so as to be rotatable about an axis which corresponds in use to the workpiece axis WSA, and in the form shown a ball bearing 60 is used for this purpose. A template carrier (not shown here, but see for example FIG. 12 / 13 or FIG. 9 / 10 / 11, reference number 42 there) is attached to the rotating dish 58. The rotating dish 58 here has a threaded hole 59 for mounting the template carrier, into which a knurled screw (reference number 49 in FIG. 9 / 10 / 11 or FIG. 12 / 13) can be screwed. In the form shown, the rotating dish 58 has a centering projection 58a, here cylindrical, against which the positioning prism 47 of the template carrier 42 abuts.

[0100] FIG. 15 shows a schematic side view, partially cut away, of a two-dimensional template 30 of the present invention, which is designed to be adjustable and therefore can be used as an alternative workpiece 3 for multiple workpieces.

[0101] The template 30 is formed of a number of part segments 61 arranged one above the other in the axial direction (vertical in FIG. 15), which can be adjusted individually in the radial direction (horizontal in FIG. 15). The part segments 61 are preferably formed as rods with a rectangular, in particular square, cross section. The part segments 61 are guided in inner guides (inner rod carrier) 62 and outer guides (outer rod carrier) 63 of the template carrier 42. The adjustment of the part segments 61 can be carried out when a fastening element, here a set screw 64, is loosened, so that the entire part segments 61 (rod package, rod bundle) with their inner ends 65 approximately replicates the cross-sectional contour 66 of the desired workpiece. The set screw 64 is then tightened, whereby the part segments 61 are fixed radially. The template carrier 42 is typically part of a temporary rotating holder (not shown in detail).

[0102] To allow the operator to easily engage the partial segments 61, the partial segments 61 are provided at their rear ends with respective bends 61a, 61b, which preferably alternately point in different directions. In Figure 15, partial segments 61 with bends 61a pointing forward (out of the plane of the drawing) alternate with partial segments 61 with bends 61b pointing backwards (into the plane of the drawing).

[0103] In FIG. 15, in side view, the obscured structure is shown as dots.

[0104] 16 shows a schematic side view of a part in the region of an alternative workpiece 3 of another exemplary embodiment of a machine tool system 1 according to the invention for carrying out the method according to the invention for collision checking in another exemplary variant. Only the main differences from the format of FIG. 1 / FIG. 2 are described.

[0105] In the illustrated embodiment, the substitute workpiece 3 is formed by a number of light beams 67 which partially replicate the cross-sectional contour of the workpiece. The light beams 67 and their intersections 70 then mark the edges and corners of the cross-sectional contour of the workpiece. The light beams 67 here are laser beams generated by a light beam source 69 (for example a commercially available laser pointer). The light beam source 69 is mounted by a light source carrier 69a on a carrier element 68, here like a bracket. By rotating the substitute workpiece 3 or the carrier element 68 about the workpiece axis WSA, the collision situation can be inspected over the entire circumference of the workpiece with very good visibility for the operator. By means of the light beams 67, the colliding edges are usually particularly easily recognized by reflection or interruption of the light of the light beams 67 (which can be made better visible through some mist or smoke due to the Tyndall effect).

[0106] The carrier element 68 can be part of a temporary rotating holder (in which case the carrier element 68 is, for example, assembled to a rotating plate of the temporary rotating holder) or can be assembled directly to the original structure (e.g., here the work spindle 4, etc.).

[0107] A linear scale 71 is attached to the carrier element 68 as an adjustment aid for adjusting the light beam source 69 .

[0108] The light beam 67 ensures that damage to the original processing components (eg, tools) that collide with the light beam 67 is avoided.

[0109] Fig. 17 shows a schematic perspective view of a model 80 capable of reproducing the inspection position or the inspection relative position for the collision inspection according to the present invention. In that case, the original machine tool as shown in Figs. 1 and 9 is not required during the collision inspection according to the present invention, thereby avoiding machine downtime. The model 80 can fully simulate the machine axes of the machine tool of Figs. 1 and 9 for the collision inspection.

[0110] The model 80 comprises a table 81 on which an intermediate slide 82 can be moved relative to a simulated machine axis X by means of a hand crank 83. An alternative work slide 84 can be moved on the intermediate slide 82 along a simulated machine axis Y by means of a hand crank 85. The two-dimensional template 30 is held on the alternative work slide 84 by a temporary rotating holder 41 and is rotatable about a simulated work axis WSA. Here, the two-dimensional template 30 forms an alternative work 3 and an alternative clamping means 29.

[0111] A model tool head 88 is supported on a vertical slide 86 which is vertically movable along a simulated machine axis Z via a hand crank 87, so as to be rotatable about a simulated machine axis A. The simulated tool axis A can be manipulated by a swivel drive 90 (including a worm gear here, not shown in detail) via a hand crank 89. The model tool head 88 holds an alternative tool 14 which can be swiveled about the simulated machine axis A. The model tool head 88 is further formed with an original gas nozzle assembly 91, which is here adjustable by means of an adjustment device 94. The vertical slide 86 is further provided with an adjustment holder 92, in which an original centering sensor 93 is here adjustable. Alternatively, it is also possible to provide the model 80 with an alternative gas nozzle assembly or an alternative centering sensor (not shown in detail).

[0112] The simulated machine axes X, Y, Z, A are provided with scales, not shown in detail, by means of which the operator can adjust the required inspection positions or inspection relative positions, possibly with a suitable offset. At each inspection position or inspection relative position, the operator can then rotate the alternative workpiece 3 by means of the temporary rotating holder 41 in order to inspect the alternative machined component E (here references 3, 29, 14) and the machined component B (here references 91, 93) for collisions.

[0113] In summary, the present invention relates to a method for collision inspection of a machining process, A method in which a plurality of machining components (B) are moved relative to one another using at least one machine axis (A, X, Y, Z) on a machine tool (2), the machining components (B) including at least one workpiece (20) and a tool (7), the workpiece (20) rotating about a work axis (WSA) and the tool (7) rotating about a tool axis (WZA) during at least a portion of a process-specific cycle, In a process-specific cycle, at least one inspection position is determined, the inspection position corresponding to a relative position of the machining component (B) set with at least one machine axis (A, X, Y, Z), and the relative position of the machining component (B) is reproduced in order to check each inspection position for collisions; In the reproduction, one or more substitute machining components (E) are used, each of which is a copy or partial copy of the corresponding machining component (B) and which includes a substitute workpiece (3) which is a partial copy of the workpiece (20), in which the workpiece (20) is reproduced over at least an axial sub-area (17) and over only a portion of the circumference of the workpiece (20), and in the reproduced relative position, the substitute workpiece (3) is rotated about the workpiece axis (WSA). The present invention provides a simple, cost-effective and safe method for collision inspection of machining processes. [Explanation of symbols]

[0114] 1 Machine tool system 2 Machine tools 2a Machine control device 2b Machine Bed 3. Alternative Work 4 Work Spindle 5 Tool Spindle 7 Tools 7a Teeth (tool) 8 Work Slides 9 Tool Slide 10 Cross Slide 11 Clamping means 12 Tool holder 13 Gas Nozzle Assembly 14 Alternative tools 15 Alternative Tool Holders 16 Half Work 16a Partial Work 17 Axial partial area 18 Axial Remaining Area 19 Substructure 20 Work 21 Teeth (work) 22 Internal teeth (work) 23 Envelope (alternative work) 24 Envelope (alternative tool) 25 Teeth (alternative tool) 26 Magnet 27 Auxiliary tools 28 Centering Sensor 29 Alternative Clamping Means 30 2D template (alternative work) 31 RFID tags 32 Alphanumeric Code 33 Identification Marking 34 Top 35 Lower 36 First Reproduction Section 37 Second Reproduction Section 38 Envelope (alternative work) 39 Envelope (alternative work) 40 Boundary Marking 41 Temporary rotating holder 42 Template Carrier 43 Offset 44 Multiple Templates 45 Half Template 46 Base Plate 46a Cover plate (top of base plate) 46b Plastic prism / sliding element (lower part of base plate) 47 Positioning prism (recess in base plate) 48 Fastening element (for template carrier) 49 Knurled screw 50 Magnet 51 Tabs 52 Fastening elements (for templates) 53 Knurled screw 55 Section 56 Section 57 Foot 58 Rotating Plate 58a Rotating plate centering protrusion 59 Threaded hole 60 ball bearings 61 Partial Segments 61a Bend part (front) 61b Bend part (rear) 62 Inner guide 63 Outer guide 64 Setscrew 65 Inner end 66 Cross-sectional profile 67 Light Beam 68 Career Elements 69 Light Beam Source 69a Light source carrier 70 intersection 71 Linear Scale 72 Optical Gap 73 Steps 74 2D Template (Alternative Tool) 75 Envelope (alternative tool) 76 Intermediate Holder 77 Lower part 78 Sliding base / ring 78a Sliding surface 78b Annular protrusion 79 Storage unit 80 Models 81 Table 82 Intermediate Slide 83 Hand Crank 84 Alternative Work Slides 85 Hand Crank 86 Vertical Slide 87 Hand Crank 88 Model Tool Head 89 Hand Crank 90 Swivel shaft drive unit 91 Gas Nozzle Assembly 92 Adjustment holder 93 Centering Sensor 94 Adjustment device (gas nozzle assembly) A Machine Axis B Machining components E Alternative Machining Components WSA Work Axis WZA Tool Axis X,Y,Z machine axis

Claims

1. 1. A method for collision inspection of a machining process, comprising: A method in which a machining process is provided with a process-specific cycle during which a plurality of machining components (B) are moved relative to one another with at least one machine axis (A, X, Y, Z) on a machine tool (2), said machining components (B) including at least one workpiece (20) and a tool (7), said workpiece (20) rotating about a work axis (WSA) and said tool (7) rotating about a tool axis (WZA) during at least a part of said process-specific cycle, In said process-specific cycle, at least one inspection location is identified which is checked for collisions with respect to said processed component (B); the inspection position corresponds to a relative position of the processed component (B) set with respect to the at least one machine axis (A, X, Y, Z); the relative positions of the processed components (B) are reproduced to check each inspection position for collisions; In the case of reproduction, one or more alternative processing components (E) are used, each of which is a copy or partial copy of the corresponding processing component (B), the one or more alternative machining components (E) include an alternative workpiece (3) which is a partial copy of the workpiece (20), in which the workpiece (20) is copied over at least an axial sub-region (17) and over only a portion of the circumference of the workpiece (20); In the reproduced relative position, the substitute work (3) is rotated about the work axis (WSA); The method comprising:

2. 2. The method according to claim 1, characterized in that the reconstruction of the relative position of the machined component (B) is performed on a model (80) of the machine tool (2) separate from the machine tool (2).

3. 2. The method according to claim 1, characterized in that the reconstruction of the relative position of the machined component (B) is performed on the machine tool (2).

4. 4. The method according to claim 3, characterized in that the machine tool (2) has at least one work spindle (4) including at least one clamping means (11), and the substitute workpiece (3) is mounted for the reproduction by means of the clamping means (11).

5. 5. The method according to claim 3, characterized in that for said reproduction, the substitute workpiece (3) is mounted on an intermediate holder (76), said intermediate holder (76) being mounted directly or indirectly on a work spindle (4).

6. 5. The method according to claim 4, characterized in that for the reproduction, the substitute workpiece (3) is mounted on an intermediate holder (76), which is directly or indirectly mounted on the work spindle (4), and which intermediate holder (76) is attached to the work spindle (4) by means of the clamping means (11) of the work spindle (4).

7. The method according to any one of claims 3 to 6, characterized in that for said reproduction, the substitute workpiece (3) is mounted on a work spindle (4) of the machine tool (2), and the work spindle (4) of the machine tool (2) is rotated in order to rotate the substitute workpiece (3) about the workpiece axis (WSA).

8. The method according to any one of claims 1 to 6, characterized in that for the reproduction, the substitute workpiece (3) is mounted on a temporary rotating holder (41) and, in order to rotate the substitute workpiece (3), the substitute workpiece (3) is rotated on the temporary rotating holder (41).

9. The substitute work (3) has an axial partial region (17) in which the work (20) is replicated only over a portion of the circumference of the work (20), and an axial remaining region (18) in which the work (20) is replicated over the entire circumference, In particular, in the axial partial region (17), the portion of the circumference has partial structures (19) spaced apart from one another in the circumferential direction.

10. The method according to any one of the preceding claims, characterized in that

10. the replacement workpiece (3) is formed as a partial workpiece (16a) which the workpiece (20) replicates over at least 1 / 3 of the circumference and at most 2 / 3 of the circumference at least in an axial partial region (17), In particular, the partial workpiece (16a) is formed as a half workpiece (16). The method according to any one of claims 1 to 9, characterized in that

11. The method according to any one of the preceding claims, characterized in that the substitute workpiece (3) fully or partially replicates only a cross-sectional contour (66) of the workpiece (20).

12. 12. The method according to claim 11, characterized in that the substitute workpiece (3) is formed by a two-dimensional template (30).

13. 13. The method according to claim 12, characterized in that the two-dimensional template (30) is formed as a multiple template (44), which fully or partially replicates the cross-sectional contours (66) of different workpieces (20) in different sections (55, 56) of the edge contour of the multiple template.

14. 13. The method according to claim 12, characterized in that the two-dimensional template (30) has mutually adjustable part segments (61) set to fully or partially replicate the cross-sectional contour (66) of the workpiece (20) and / or clamping means.

15. 12. The method according to claim 11, characterized in that the substitute workpiece fully or partially replicates the cross-sectional contour (66) of the workpiece and / or the clamping means by means of a light beam (67), in particular a laser beam.

16. 16. The method according to claim 15, characterized in that the light beams (67) replicate edges of the cross-sectional contour (66) of the workpiece and / or the clamping means and / or the intersections (70) of the light beams (67) replicate corner points in the cross-sectional contour (66) of the workpiece (20) and / or the clamping means.

17. The one or more substitute machining components (E) include a substitute tool (14) that is a copy or partial copy of the tool (7).

10. The method according to any one of the preceding claims, characterized in that

18. the alternative tool (14) is a partial copy of the tool (7), in which the tool (7) is copied over at least an axial partial area and over only a portion of the circumference of the tool (7); In the reproduced relative position, the substitute tool (14) is rotated about the tool axis (WZA). The method according to claim 17, characterized in that

19. 19. The method according to claim 17 or 18, characterized in that the one or more alternative machining components (E) comprise an alternative tool holder (15) which is a replica or partial replica of a tool holder (12) used for mounting the tool (7) on a tool spindle (5) of the machine tool (2).

20. 10. The method according to any one of the preceding claims, characterized in that the one or more alternative machining components (E) comprise alternative clamping means (29) which are a replica or partial replica of clamping means (11) used to hold the workpiece (20) on a work spindle (4) of the machine tool (2).

21. the alternative clamping means (29) is rotated together with the alternative workpiece (3) in the recreated relative position; In particular, the alternative clamping means (29) and the alternative workpiece (3) are formed by a common two-dimensional template (30). The method according to claim 20, characterized in that

22. 10. A method according to any one of the preceding claims, characterized in that in one or more alternative machined components (E), the toothings (7a; 21) of the corresponding machined component (B) are fully or partially replaced by the envelope curves (38, 39; 75) or surfaces (23, 24) of the toothings (7a; 21).

23. 10. The method according to claim 1, characterized in that the workpiece (20) which is partially replicated by the alternative workpiece (3) is an internally toothed workpiece (20).

24. 10. A method according to any one of the preceding claims, characterized in that for collision checking, at least one light gap (72) is observed when rotating the substitute workpiece (3).

25. the one or more alternative processing components (E) include at least one alternative processing component (E) having a first replicated section (36) and a second replicated section (37), the replicated sections (36, 37) replicating two similarly formed sections of the corresponding processing component (B), the type of replication being different between the first replicated section (36) and the second replicated section (37); In particular, said similar sections of said machined component carry a toothing (7a; 21), said first replica section (36) replicating the tip circle of said toothing (7a; 21) and said second replica section (37) replicating the root circle of said toothing (7a; 21). A method according to any one of the preceding claims.

26. 10. A method according to any one of the preceding claims, characterized in that at least one boundary marking (40) is applied to at least one alternative processing component (E), said boundary marking indicating boundaries of the structure of said associated processing component (B) that are not replicated or not fully replicated in said alternative processing component (E).

27. an identification marking (33) is applied to at least one alternative processing component (E), said identification marking allowing identification of said alternative processing component (E) and / or allocation of said alternative processing component (E) to said corresponding processing component (B); In particular, said identification marking (33) is human readable and / or machine readable; In particular, said identification marking (33) comprises an alphanumeric code (32) and / or a QR code and / or a bar code and / or an RFID tag (31).

10. The method according to any one of the preceding claims, characterized in that

28. 10. The method according to claim 9, characterized in that the processing component (B) comprises at least one auxiliary tool (27), in particular the at least one auxiliary tool (27) comprises a gas nozzle assembly (13; 91) and / or a suction nozzle assembly and / or a cooling lubricant nozzle assembly and / or a centering sensor (28; 93).

29. 1. A method for preparing a processing process, comprising the steps of: The method includes the collision inspection method according to claim 28, Furthermore, for at least one inspection position, a function optimization of at least one auxiliary tool (27) is performed in the reproduced relative position, in particular by positioning, alignment and / or selection of said auxiliary tool (27). method.

30. A machine tool system (1) designed to carry out the method according to any one of the preceding claims, said machine tool system (1) comprising a machine tool (2) for machining at least one workpiece (20) and comprising one or more alternative machining components (E), each of which is a copy or a partial copy of a corresponding machining component (B) of said machine tool (2), the one or more alternative machining components (E) include an alternative workpiece (3) which is a partial copy of the workpiece (20), in which the workpiece (20) is copied over at least an axial sub-region (17) and over only a portion of the circumference of the workpiece (20); Machine tool systems.

31. said machine tool (2) comprising an electronic machine control (2a) programmed to approach all identified inspection positions related to the inspection relative positions of an alternative machining component (E) and / or a machining component (B) arranged on said machine tool (2) in order to carry out the method according to any one of the preceding claims, In particular, the inspection relative position is the same as the relative position of the machining component (B) in a process-specific cycle, or the inspection relative position corresponds to the relative position of the machining component (B) in a process-specific cycle plus an offset (43), the offset resulting from the mounting of each alternative machining component (E) on the machine tool (2) differently from the mounting of the corresponding original machining component (B).

31. Machine tool system (1) according to claim 30, characterized in that

32. Use of an alternative machining component (E) in a method according to any one of claims 1 to 29 or in a machine tool system (1) according to any one of claims 30 or 31, comprising: The alternative processing component (E) is a copy or partial copy of the corresponding processing component (B), In particular, said alternative machining component (E) is an alternative workpiece (3) for a corresponding workpiece (20), in which said workpiece (20) is replicated at least over an axial partial area (17) and over only a portion of the circumference of said workpiece (20); use.

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