Control device for gear machining equipment and gear machining equipment

Abstract

The present invention provides a control device for a gear machining apparatus and a gear machining apparatus that can appropriately manage the phase difference between the phase of a pre-machined area and the phase of a subsequent-machined area formed on the circumferential surface of a workpiece. [Solution] The control device of the gear machining apparatus 1 includes a control unit that controls the synchronous rotation and relative movement of the tool 200 that machines the workpiece 100 and the workpiece 100 so that a plurality of machined areas 101, including a leading machined area 110 and a trailing machined gear 121 as a trailing machined area 120, are formed on the workpiece 100. The control device includes a phase detection unit 310 that detects the phase of the leading machined area 110 after the start of machining of the leading machined area 110 and before the finishing of the leading machined area 110, and detects the phase of the trailing machined area 120 after the start of machining of the trailing machined area 120 and before the finishing of the trailing machined area 120.

Description

Technical Field

[0001] The present disclosure relates to a control device for a gear processing apparatus and a gear processing apparatus.

Background Art

[0002] There is known a gear processing apparatus that detects the phase of a tool after replacement of the tool for gear processing. For example, the gear processing apparatus described in Patent Document 1 detects the phase of the tool by detecting a detected portion of a holder attachment portion.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] When forming a plurality of processing portions on the peripheral surface of one workpiece, it is preferable that the phase difference between the phase of the preceding processing portion and the phase of the succeeding processing portion can be appropriately managed.

Means for Solving the Problems

[0005] The control device of the present disclosure is a control device for a gear processing apparatus including a control unit that controls synchronous rotation and relative movement of a tool for processing the workpiece and the workpiece so that a plurality of processing portions including a preceding processing portion and a succeeding processing gear as a succeeding processing portion are formed on the workpiece, and includes a phase detection unit that detects the phase of the preceding processing portion after the start of processing of the preceding processing portion and before the finish machining of the preceding processing portion, and detects the phase of the succeeding processing portion after the start of processing of the succeeding processing portion and before the finish machining of the succeeding processing portion.

[0006] According to the control device described above, the phase of the preceding processed area and the phase of the succeeding processed area are detected, allowing for appropriate management of the phase difference between the phases of the preceding and succeeding processed areas. Furthermore, the phase of the preceding processed area can be determined at an earlier stage compared to detecting the phase of the preceding processed area after the completion of the finishing process of the preceding processed area. Similarly, the phase of the succeeding processed area can be determined at an earlier stage compared to detecting the phase of the succeeding processed area after the completion of the finishing process of the succeeding processed area. [Effects of the Invention]

[0007] The control device and gear machining apparatus of the present disclosure can appropriately manage the phase difference between the phase of a pre-machined portion and the phase of a post-machined portion formed on the circumferential surface of a workpiece. [Brief explanation of the drawing]

[0008] [Figure 1] This is a schematic diagram of a gear processing apparatus according to the embodiment, viewed from above. [Figure 2] Figure 1 is a schematic diagram showing a perspective view of the main body, tool holder, and workpiece holder of the gear machining apparatus. [Figure 3] Figure 1 is a block diagram showing the electrical configuration of a gear machining apparatus. [Figure 4] This is a schematic diagram showing a portion of the reference circle of the preceding gear before finishing, and a portion of the reference circle and base circle of the following gear before finishing, as seen in Figure 1. [Figure 5] This is an enlarged view showing the relationship between the phase of the leading gear and the phase of the trailing gear in Figure 4. [Figure 6] Figure 5 is a schematic diagram showing an example of a pre-machined gear being roughly machined by a tool. [Figure 7] Figure 6 is a schematic diagram showing an example of a pre-machined gear being finished by a tool. [Figure 8] Figure 5 is a schematic diagram showing an example of how the phase detection unit detects the phase of the roughly machined gear shown in Figure 5. [Figure 9]Figure 2 is a flowchart showing an example of control of a gear machining device by the control unit. [Modes for carrying out the invention]

[0009] (Embodiment) Referring to Figures 1 to 9, the control device 300 and the gear processing device 1 of the gear processing device 1 will be described. Hereinafter, directions relating to the gear processing device 1 will be described as the first horizontal direction X, the second horizontal direction Y perpendicular to the first horizontal direction X, and the vertical direction Z perpendicular to both the first horizontal direction X and the second horizontal direction Y.

[0010] <Gear Processing Equipment> The gear machining apparatus 1 is a device that forms multiple machined parts 101 on a workpiece 100 by cutting the workpiece 100 with a tool 200. The gear machining apparatus 1 cuts the workpiece 100 with the tool 200 by moving the tool 200 relative to the workpiece 100 while synchronously rotating the workpiece 100 and the tool 200.

[0011] <Work> As shown in Figures 1 and 2, the workpiece 100 is substantially cylindrical. The workpiece 100 has a workpiece rotation axis C1. The workpiece rotation axis C1 is aligned with the vertical direction Z. The workpiece 100 is installed in the gear machining apparatus 1 so as to rotate around the workpiece rotation axis C1.

[0012] Multiple machining areas 101 are formed on the workpiece 100. The machining areas 101 are formed on the outer or inner surface of the workpiece 100. The machining areas 101 include a pre-machined area 110 and a post-machined area 120.

[0013] The pre-processed portion 110 is the part of the workpiece 100 that is formed before the subsequent processing portion 120. When the workpiece 100 is installed in the gear processing device 1, the pre-processed portion 110 and the subsequent processing portion 120 are formed with a gap between them in the vertical direction Z.

[0014] The pre-processed part 110 and the post-processed part 120 include the parts processed by the tool 200. The parts processed by the tool 200 include the parts where the processing planned for the pre-processed part 110 or the post-processed part 120 is in progress, and the parts where the planned processing has been completed.

[0015] On the workpiece 100, a processing part 101 other than the pre-processed part 110 and the post-processed part 120 may be formed. When three or more processing parts 101 are formed on the workpiece 100, the pre-processed part 110 is the processing part 101 where the processing starts first among the plurality of processing parts 101, or the processing part 101 where the processing starts after the second and before the post-processed part 120.

[0016] Two or more post-processed parts 120 may be set for one pre-processed part 110. For example, when four or more processing parts 101 are formed on the workpiece 100, one or more groups including one pre-processed part 110 and one or more post-processed parts 120 are set.

[0017] In this embodiment, both the pre-processed part 110 and the post-processed part 120 are gears. Hereinafter, the gear as the pre-processed part 110 is described as the pre-processed gear 111, and the gear as the post-processed part 120 is described as the post-processed gear 121.

[0018] In an example shown in FIG. 2, two processing parts 101, namely the pre-processed gear 111 and the post-processed gear 121, are formed on the workpiece 100. The pre-processed gear 111 is a helical gear formed on the outer peripheral surface of the workpiece 100. The post-processed gear 121 is a helical gear formed on the outer peripheral surface of the workpiece 100. The pre-processed gear 111 is formed below the workpiece 100 than the post-processed gear 121. The pre-processed gear 111 may be formed above the workpiece 100 than the post-processed gear 121.

[0019] <Tool> As shown in Figure 2, the tool 200 is a skiving cutter. The gear machining apparatus 1 forms the machined portion 101 by skiving. The tool 200 has a tool rotation axis C2. The tool 200 rotates around the tool rotation axis C2. The tool 200 tilts the tool rotation axis C2 by a predetermined angle with respect to the work rotation axis C1 of the workpiece 100 and skives the workpiece 100.

[0020] As shown in Figures 2, 6, and 7, the tool 200 has a plurality of cutters 210. Each cutter 210 includes a cutter body 211 and a tooth tip chamfering section 212. The cutter body 211 cuts the workpiece 100. The tooth tip chamfering section 212 is provided at the base of the cutting edge of the cutter body 211. The tooth tip chamfering section 212 chamfers the tooth tip when the cutting depth of the workpiece 100 by the cutter 210 exceeds a predetermined depth.

[0021] The machining stages are defined based on the depth of cut made by the cutter 210 into the workpiece 100. The machining stages include rough machining and finish machining. Rough machining is the machining stage in which the workpiece 100 is machined from the start of machining to a depth of cut smaller than a predetermined depth. Finish machining is the machining stage in which the depth of cut is greater than or equal to a predetermined depth and up to a target depth of cut. In finish machining, the tooth tips of the leading gear 111 and the trailing gear 121 are chamfered.

[0022] Figure 6 shows the relationship between the tool 200 and the leading gear 111 during rough machining. During rough machining, the tooth tip chamfer portion 212 does not contact the tooth tip of the leading gear 111, so chamfering is not performed.

[0023] Figure 7 shows the relationship between the tool 200 and the leading gear 111 during finishing. The dashed line in Figure 7 indicates the portion of the leading gear 111's tooth tip that is chamfered during finishing. From the state shown in Figure 7, as the cutting depth of the cutter 210 into the workpiece 100 increases further, the tooth tip chamfer portion 212 comes into contact with the tooth tip of the leading gear 111, and chamfering is performed. Figures 6 and 7 show the relationship between the tool 200 and the leading gear 111 as an example, but the relationship between the tool 200 and the trailing gear 121 is similar.

[0024] <Main body> As shown in Figures 1 and 2, the gear machining apparatus 1 comprises a main body 10, a workpiece holding section 20, and a tool holding section 30. The workpiece holding section 20 and the tool holding section 30 are provided on the main body 10. The main body 10 includes a base section 11, a first movable section 12, and a second movable section 13. The base section 11 is located below the first movable section 12 and the second movable section 13 in the vertical direction Z. The workpiece holding section 20 and the tool holding section 30 are located above the base section 11 in the vertical direction Z.

[0025] The first movable part 12 is provided on the base part 11. The first movable part 12 moves on the base part 11 in a first horizontal direction X. The first horizontal direction X is approximately the longitudinal direction of the base part 11. The first movable part 12 moves in the first horizontal direction X so as to approach the workpiece 100 or so as to move away from the workpiece 100.

[0026] The second movable part 13 is provided on the first movable part 12. The second movable part 13 is provided on the side surface 12A of the first movable part 12. The side surface 12A of the first movable part 12 faces the tool holding part 30. The second movable part 13 moves along the side surface 12A of the first movable part 12 in the vertical direction Z. The second movable part 13 moves in the vertical direction Z such that the second movable part 13 approaches the base part 11, or moves away from the base part 11.

[0027] The main body 10 further includes a rotating part 14. The rotating part 14 is provided on the side surface 13A of the second movable part 13. The side surface 13A of the second movable part 13 faces the tool holding part 30. The rotating part 14 has a pivot axis C3. The pivot axis C3 of the rotating part is along a first horizontal direction X. The rotating part 14 rotates about the pivot axis C3. The rotating part 14 is, for example, substantially circular.

[0028] The main body 10 further includes a tool holder support 15. The tool holder support 15 is provided on the rotating part 14 so as to rotate integrally with the rotating part 14. The tool holder support 15 extends outward from the rotating part 14.

[0029] The tool holder support 15 supports the tool holder 30 so that it moves in the direction of tool holder movement W. The tool holder 30 moves along the side surface of the tool holder support 15. The tool rotation axis C2 is aligned with the direction of tool holder movement W.

[0030] <Tool holding part> The tool holder 30 rotatably holds the tool 200. The tool holder 30 has a tool holder body 31 and a tool rotation shaft 32. The tool rotation shaft 32 is provided on the tool holder body 31 so as to rotate relative to the tool holder body 31. The tool 200 is attached to the tool rotation shaft 32. The rotational axis of the tool rotation shaft 32 substantially coincides with the tool rotation axis C2.

[0031] The tool holder body 31 is supported by the tool holder support 15 so as to move in the tool holder movement direction W. The tool holder body 31 moves in the tool holder movement direction W so as to move the tool holder 30 closer to the workpiece 100, or so as to move the tool holder 30 away from the workpiece 100.

[0032] <Tool change device> As shown in Figure 1, the gear machining apparatus 1 further comprises a tool changing device 40. The tool changing device 40 is a device for replacing a tool 200 held in the tool holding section 30 with another tool 200. The tool changing device 40 has a storage section 41 and a replacement section 42.

[0033] Multiple tools 200 are housed in the storage section 41. The multiple tools 200 include a first tool for machining the leading gear 111 and a second tool for machining the trailing gear 121. The exchange section 42 exchanges the tools 200 held in the tool holding section 30 with the tools 200 housed in the storage section 41.

[0034] <Workpiece holding section> As shown in Figures 1 and 2, the workpiece holder 20 rotatably holds the workpiece 100. The workpiece holder 20 is provided on the base portion 11 at a distance from the main body portion 10. The workpiece holder 20 extends upward from the base portion 11 in the vertical direction Z. The workpiece holder 20 is substantially cylindrical in shape.

[0035] The workpiece holder 20 comprises a workpiece holder body 21 and a workpiece rotation axis 22. The workpiece rotation axis 22 is provided on the workpiece holder body 21 so as to rotate relative to the workpiece holder body 21. The workpiece 100 is attached to the workpiece rotation axis 22. The rotational axis of the workpiece rotation axis 22 substantially coincides with the workpiece rotation axis C1.

[0036] <Drive Unit> As shown in Figures 1 to 3, the gear machining apparatus 1 comprises a plurality of drive units 50. The drive units 50 drive each movable part of the gear machining apparatus 1 in order to machine the workpiece 100 with a tool 200. The drive units 50 include actuators. The actuators include electric motors or solenoid motors. The drive units 50 are connected to the control unit 301 by wire or wireless. The plurality of drive units 50 include a first movable part drive unit 51, a second movable part drive unit 52, a rotating part drive unit 53, a tool holding part drive unit 54, a workpiece rotation axis drive unit 55, a tool rotation axis drive unit 56, and a replacement part drive unit 57.

[0037] The first movable part drive unit 51 drives the first movable part 12 so that it moves in the first horizontal direction X. The first movable part drive unit 51 is electrically connected to the control unit 301 by wire or wireless.

[0038] The second movable part drive unit 52 drives the second movable part 13 so that it moves in the vertical direction Z. The second movable part drive unit 52 is electrically connected to the control unit 301 by wire or wireless.

[0039] The rotating part drive unit 53 drives the rotating part 14 so that it rotates around the rotating part pivot axis C3. The rotating part drive unit 53 is electrically connected to the control unit 301 by wire or wireless.

[0040] The tool holder drive unit 54 drives the tool holder 30 so that it moves in the tool holder movement direction W. The tool holder drive unit 54 is electrically connected to the control unit 301 by wire or wireless.

[0041] The workpiece rotation axis drive unit 55 drives the workpiece rotation axis 22 so that the workpiece 100 rotates around the workpiece rotation axis C1. The workpiece rotation axis drive unit 55 is electrically connected to the control unit 301 by wire or wireless.

[0042] The tool rotation shaft drive unit 56 drives the tool rotation shaft 32 so that it rotates around the tool rotation axis C2. The tool rotation shaft drive unit 56 is electrically connected to the control unit 301 by wire or wireless.

[0043] The replacement unit drive unit 57 drives the replacement unit 42 so that the replacement unit 42 replaces the tool 200. The replacement unit drive unit 57 is electrically connected to the control unit 301 by wire or wireless.

[0044] The gear machining apparatus 1 is powered by a power supply source 60. The power supply source 60 supplies power to the control unit 301 and the drive unit 50. The power supply source 60 is, for example, an external power supply.

[0045] <Control device> As shown in Figures 2 and 3, the gear machining apparatus 1 includes a control device 300. The control device 300 includes a control unit 301 and a storage unit 302. The control unit 301 includes a processing unit that executes a predetermined control program.

[0046] The storage unit 302 includes non-volatile memory and volatile memory. The storage unit 302 is communicated with the control unit 301 by wire or wireless means. The storage unit 302 stores various information used for controlling the gear processing machine 1.

[0047] As shown in Figures 1 to 3 and Figure 8, the control device 300 includes a phase detection unit 310. The phase detection unit 310 includes a phase calculation unit and a detection sensor 311. The detection sensor 311 is a non-contact type sensor. Examples of non-contact type sensors include eddy current sensors, laser sensors, and electromagnetic pickups. In this embodiment, the phase detection unit 310 includes an eddy current sensor. The detection sensor 311 is provided in the tool holding unit 30.

[0048] The detection sensor 311 detects the shapes of the preceding machined part 110 and the succeeding machined part 120, respectively. Figure 8 shows an example in which the detection sensor 311 detects the shape of the preceding machined gear 111. The dashed line in Figure 8 schematically represents the high-frequency magnetic field of the eddy current sensor. The detection sensor 311 detects, for example, the distance from the tooth surface of the preceding machined gear 111 to the detection sensor 311. The detection sensor 311 also detects, for example, the distance from the tooth surface of the succeeding machined gear 121 to the detection sensor 311.

[0049] The phase calculation unit calculates the rotation angle of a predetermined portion of the first-machined portion 110 from a predetermined reference position P0 on the workpiece holding unit 20 as the phase of the first-machined portion 110. The phase calculation unit also calculates the rotation angle of a predetermined portion of the second-machined portion 120 from a predetermined reference position P0 on the workpiece holding unit 20 as the phase of the second-machined portion 120. Information regarding the reference position P0 is stored in advance in the storage unit 302. The reference position P0 may be set with respect to the workpiece 100.

[0050] As shown in Figures 2 to 5, the phase detection unit 310 detects the phases of the leading teeth 112 of the leading gear 111 and the trailing teeth 122 of the trailing gear 121. The phase calculation unit calculates the leading tooth rotation angle A1 from the reference position P0 to the tooth width center position PA of the leading tooth 112. The phase calculation unit also calculates the trailing tooth rotation angle A2 from the reference position P0 to the tooth width center position PB of the trailing tooth 122.

[0051] The phase detection unit 310 detects the phase of the pre-machined portion 110 after the start of machining of the pre-machined portion 110 and before the finishing of the pre-machined portion 110. "After the start of machining of the pre-machined portion 110" means from the point onward when cutting of the workpiece 100 by the tool 200 begins in order to form the pre-machined portion 110 on the workpiece 100. "Before the finishing of the pre-machined portion 110" means before the point onward when cutting of the workpiece 100 by the tool 200 begins in order to perform the finishing of the pre-machined portion 110, after the start of machining of the pre-machined portion 110.

[0052] In this embodiment, the phase detection unit 310 detects the phase of the leading gear 111 after the start of machining and before the finishing of the leading gear 111. Specifically, the phase detection unit 310 detects the phase of the leading teeth 112 of the leading gear 111 after the start of machining and before the finishing of the leading gear 111.

[0053] The phase detection unit 310 detects the phase of the subsequent machining area 120 after machining of the subsequent machining area 120 has started and before finishing of the subsequent machining area 120. After machining of the subsequent machining area 120 has started means from the point in time when cutting of the workpiece 100 by the tool 200 has started in order to form the subsequent machining area 120 on the workpiece 100. Before finishing of the subsequent machining area 120 means before the point in time when cutting of the workpiece 100 by the tool 200 has started in order to perform finishing after machining of the subsequent machining area 120 has started.

[0054] In this embodiment, the phase detection unit 310 detects the phase of the trailing gear 121 after machining has started and before finishing of the trailing gear 121. Specifically, the phase detection unit 310 detects the phase of the trailing teeth 122 of the trailing gear 121 after machining has started and before finishing of the trailing gear 121.

[0055] As shown in Figures 1 to 3 and Figure 8, the control device 300 further comprises a tool phase detection unit 320. The tool phase detection unit 320 includes a tool phase calculation unit and a tool phase detection sensor. The tool phase detection sensor detects the shape of the part to be detected provided on the tool 200.

[0056] The tool phase detection sensor is a non-contact type sensor. Examples of non-contact types include eddy current sensors, laser sensors, and electromagnetic pickups. In this embodiment, the tool phase detection sensor includes an eddy current sensor. The tool phase detection sensor may also include a contact type sensor such as a touch probe sensor.

[0057] The tool phase calculation unit calculates the rotation angle of the tool 200 from the tool reference position, which is set in advance in the tool holding unit 30, to the detected part provided on the tool 200, as the phase of the tool 200. Information regarding the tool reference position is stored in advance in the storage unit 302.

[0058] The part to be detected on the tool 200 includes one of the multiple blades of the cutter 210. Since all of the multiple blades of the cutter 210 have the same shape, the blade detected by the tool phase detection sensor may be any of them. The tool phase detection sensor detects the rotation angle of one of the multiple blades from the tool reference position. The part to be detected may be a recess, through hole, groove, or flat surface formed by cutting a part of the tool 200.

[0059] The control unit 301 controls the synchronous rotation and relative movement of the tool 200 and the workpiece 100 so that a plurality of machining areas 101, including a leading machining area 110 and a trailing machining gear 121 as a trailing machining area 120, are formed on the workpiece 100. The control unit 301 controls the synchronous rotation and relative movement of the tool 200 and the workpiece 100 by controlling the tool holding unit 30 and the workpiece holding unit 20.

[0060] Specifically, the control unit 301 controls the first movable part drive unit 51 to move the tool 200 relative to the workpiece 100 in the first horizontal direction X. The control unit 301 controls the rotating part drive unit 53 to tilt the tool rotation axis C2 by a predetermined angle with respect to the workpiece rotation axis C1. The control unit 301 controls the tool holding part drive unit 54 to move the tool 200 relative to the workpiece 100 in the tool holding part movement direction W.

[0061] The control unit 301 controls the workpiece rotation axis drive unit 55 and the tool rotation axis drive unit 56 to rotate the tool 200 and the workpiece 100 synchronously. The control unit 301 controls the second movable part drive unit 52 to move the tool 200 relative to the workpiece 100 in the vertical Z direction.

[0062] The control unit 301 compares the phase of the leading teeth 112 of the leading gear 111 with the phase of the trailing teeth 122 of the trailing gear 121. The control unit 301 calculates the phase difference d1 between the phase of the leading teeth 112 of the leading gear 111 and the trailing teeth 122 of the trailing gear 121. The phase difference d1 is the difference between the rotation angle A1 of the leading teeth and the rotation angle A2 of the trailing teeth.

[0063] The control unit 301 compares the phase difference d1 with a predetermined phase difference to determine whether or not it is possible to correct the phase difference d1 during the finishing process of the successor gear 121. Correcting the phase difference d1 means that during the finishing process of the successor gear 121, a portion of the successor gear 121 is cut by controlling at least one of the relative movement and synchronous rotation between the workpiece holding unit 20 and the tool holding unit 30, thereby cutting off a portion of the successor gear 121 equal to the phase difference d1.

[0064] The control unit 301 determines that if the phase difference d1 is smaller than a predetermined phase difference, then correction of the phase difference d1 is possible. If the phase difference d1 is greater than or equal to the predetermined phase difference, then even if the machining of the workpiece 100 continues, there is a risk that teeth or tooth grooves of the designed shape cannot be formed. For this reason, the control unit 301 determines that if the phase difference d1 is greater than or equal to the predetermined phase difference, then correction of the phase difference d1 is not possible.

[0065] The predetermined phase difference is set based on the correctable amount CA. A phase difference d1 is correctable when it is smaller than the correctable amount CA. A phase difference d1 is not correctable when it is greater than or equal to the correctable amount CA. The correctable amount CA is calculated by the following equation (1).

[0066]

number

[0067] Figure 4 shows a portion of the leading gear 111 and a portion of the trailing gear 121 after finishing. In Figure 4, the reference circles of the leading gear 111 and the trailing gear 121 are shown by dashed lines. The reference circle radius r1 of the leading gear 111 is greater than the reference circle radius r2 of the trailing gear 121. The leading gear 111 and the trailing gear 121 have involute tooth profiles. In Figure 4, the base circle of the trailing gear 121 is shown by a dashed line. In equation (1), Rb is the base circle radius Rb of the trailing gear 121.

[0068] Figure 5 shows the first-machined gear 111 and the second-machined gear 121 after finishing with solid lines. Figure 5 shows the second-machined gear 121 before finishing with a dashed line. In equation (1), d2 is the difference d2 between the radius of the root circle of the second-machined gear 121 before finishing and the radius of the root circle of the second-machined gear 121 after finishing.

[0069] Figure 5 shows the root circles of the successor gear 121 before finishing and the successor gear 121 after finishing, indicated by dashed lines. The radius of the root circle of the successor gear 121 before finishing is larger than the radius of the root circle of the successor gear 121 after finishing. Figure 5 shows the reference circle of the successor gear 121 before finishing, indicated by a dashed line. In equation (1), AN is the pressure angle AN of the successor gear 121 before finishing.

[0070] If it is determined that the phase difference d1 can be corrected, the control unit 301 controls the synchronous rotation and relative movement of the tool 200 and the workpiece 100 so as to reduce the phase difference d1 between the phase of the leading gear 111 and the phase of the trailing gear 121. The control unit 301 controls the synchronous rotation and relative movement of the tool 200 and the workpiece 100, for example, by controlling the tool holder 30 and the workpiece holder 20 so as to reduce the phase difference d1.

[0071] Specifically, if it is determined that the phase difference d1 can be corrected, the control unit 301 controls, for example, the second movable part drive unit 52 to change the phase of the tool 200 relative to the workpiece 100 and perform finishing work on the subsequent gear 121.

[0072] The control unit 301 will not perform finishing machining on the subsequent gear 121 if the phase difference d1 is greater than or equal to a predetermined phase difference. In other words, the control unit 301 will terminate machining of the workpiece 100 if the phase difference d1 is greater than or equal to a predetermined phase difference. The predetermined phase difference is set based on the correctable amount CA. The control unit 301 may be configured not to perform finishing machining on the subsequent gear 121 if the phase difference d1 is greater than or equal to the correctable amount CA.

[0073] <Gear Manufacturing Method> An example of a gear machining method using the gear machining apparatus 1 of this embodiment will be described with reference to Figures 1 to 3 and Figure 9. When the control unit 301 receives a signal to start the gear machining process, it executes the gear machining process according to the flowchart shown in Figure 9.

[0074] In step S11, the control unit 301 roughly machines the workpiece 100 with the first tool of the tool 200 for machining the leading gear 111. Preferably, the control unit 301 machines the workpiece 100 up to just before chamfering begins on the leading gear 111. After roughly machining the workpiece 100 with the first tool, the control unit 301 proceeds to step S12.

[0075] In step S12, the control unit 301 measures the phase of the leading gear 111. Specifically, the control unit 301 measures the phase of the leading gear 111 by controlling the phase detection unit 310 to measure the phase of the leading teeth 112 of the leading gear 111. After measuring the phase of the leading gear 111, the control unit 301 proceeds to step S13.

[0076] In step S13, the control unit 301 finishes machining the leading gear 111 with the first tool. In this embodiment, the tool 200 is not changed between the rough machining and the finish machining of the leading gear 111. Therefore, the phases of the leading teeth 112 of the leading gear 111 coincide after rough machining and after finish machining. After finishing machining the leading gear 111 with the first tool, the control unit 301 proceeds to step S14.

[0077] In step S14, the control unit 301 replaces the tool 200 from the first tool to the second tool. Specifically, the control unit 301 replaces the first tool with the second tool by controlling the replacement unit drive unit 57. The second tool is used to machine the subsequent gear 121. After replacing the tool 200, the control unit 301 proceeds to step S15.

[0078] In step S15, the control unit 301 measures the phase of the second tool. Specifically, the control unit 301 controls the tool phase detection unit 320 to measure the phase of the second tool. After measuring the phase of the tool 200, the control unit 301 proceeds to step S16.

[0079] In step S16, the control unit 301 roughly machines the workpiece 100 with the second tool. Preferably, the control unit 301 machines the workpiece 100 up to just before the chamfering process begins with the successor machining gear 121. After roughly machining the workpiece 100 with the second tool, the control unit 301 proceeds to step S17.

[0080] In step S17, the control unit 301 measures the phase of the trailing gear 121. Specifically, the control unit 301 measures the phase of the second tool by controlling the phase detection unit 310 to measure the phase of the trailing teeth 122 of the trailing gear 121. After measuring the phase of the trailing gear 121, the control unit 301 proceeds to step S18.

[0081] In step S18, the control unit 301 calculates the correctable amount CA and proceeds to step S19.

[0082] In step S19, the control unit 301 determines whether the phase difference d1 is smaller than a predetermined phase difference. For example, if the phase difference d1 is smaller than the correctable amount CA calculated in step S18, the control unit 301 determines that the phase difference d1 is smaller than the predetermined phase difference. If the phase difference d1 is greater than or equal to the predetermined phase difference, the control unit 301 proceeds to step S20. If the phase difference d1 is smaller than the predetermined phase difference, the control unit 301 terminates the process.

[0083] In step S20, the control unit 301 finishes machining the trailing gear 121 with the second tool and terminates the process. Specifically, the control unit 301 finishes machining the trailing gear 121 with the second tool so that the phase difference d1 decreases. In this embodiment, the tool 200 is not changed between the rough machining and the finish machining of the trailing gear 121. Therefore, the phases of the trailing teeth 122 of the trailing gear 121 coincide after rough machining and after finish machining.

[0084] (Effects of the embodiment) The control device 300 and the gear processing apparatus 1 of this embodiment have the following advantages.

[0085] (1) The control device 300 comprises a control unit 301 and a phase detection unit 310. The control unit 301 controls the synchronous rotation and relative movement of the tool 200 that processes the workpiece 100 and the workpiece 100 so that a plurality of processing areas 101, including a leading processing area 110 and a trailing processing gear 121 as a trailing processing area 120, are formed on the workpiece 100. The phase detection unit 310 detects the phase of the leading processing area 110 after the start of processing of the leading processing area 110 and before the finishing of the leading processing area 110. The phase detection unit 310 detects the phase of the trailing processing area 120 after the start of processing of the trailing processing area 120 and before the finishing of the trailing processing area 120.

[0086] With the above configuration, the control device 300 detects the phase of the preceding machining area 110 and the phase of the succeeding machining area 120, so it can appropriately manage the phase difference d1 between the phase of the preceding machining area 110 and the phase of the succeeding machining area 120.

[0087] Furthermore, compared to detecting the phase of the preceding processed area 110 after the finishing process of the preceding processed area 110 is completed, the phase of the preceding processed area 110 can be determined at an earlier time. Also, compared to detecting the phase of the succeeding processed area 120 after the finishing process of the succeeding processed area 120 is completed, the phase of the succeeding processed area 120 can be determined at an earlier time.

[0088] (2) The pre-machined portion 110 includes the pre-machined gear 111. The phase detection unit 310 detects the phase of the pre-machined gear 111 after the start of machining of the pre-machined gear 111 and before the finishing of the pre-machined gear 111. The phase detection unit 310 detects the phase of the trailing gear 121 after the start of machining of the trailing gear 121 and before the finishing of the trailing gear 121.

[0089] With the above configuration, the phase of the leading gear 111 can be determined at an earlier timing compared to the case where the phase of the leading gear 111 is detected after the finishing of the leading gear 111 is completed. Also, the phase of the trailing gear 121 can be determined at an earlier timing compared to the case where the phase of the trailing gear 121 is detected after the finishing of the trailing gear 121 is completed.

[0090] Furthermore, if the finishing process includes chamfering, measuring the phase of the preceding gear 111 after the finishing process may result in an inaccurate measurement of the phase of the preceding gear 111 due to the influence of the chamfering process. The phase detection unit 310 in this embodiment detects the phase of the preceding gear 111 before the finishing process, making it less susceptible to the influence of chamfering. Therefore, the accuracy of phase detection by the phase detection unit 310 can be improved.

[0091] (3) The control unit 301 controls the synchronous rotation and relative movement of the tool 200 and the workpiece 100 so as to reduce the phase difference d1 between the phase of the leading gear 111 and the phase of the trailing gear 121.

[0092] According to the above configuration, the control unit 301 can reduce the phase difference d1 between the phase of the subsequent processing area 120 and the preceding processing area 110.

[0093] Furthermore, in this embodiment, the phase difference d1 is corrected during the finishing process of the subsequent gear 121. Since the phase of the subsequent gear 121 is detected before the finishing process, the correction can be effectively performed during the finishing process.

[0094] (4) If the phase difference d1 is greater than or equal to a predetermined phase difference, the control unit 301 will not perform the finishing work on the subsequent gear 121 for which the phase difference d1 was detected.

[0095] The control unit 301 does not perform finishing work on the subsequent gear 121 if the phase difference d1 is greater than or equal to a predetermined phase difference, thus eliminating the need for finishing work when it is not possible to form teeth or tooth grooves of the designed shape.

[0096] (5) The gear processing apparatus 1 comprises a control device 300, a workpiece holding unit 20 for rotatably holding the workpiece 100, and a tool holding unit 30 for rotatably holding the tool 200.

[0097] According to the above configuration, the gear machining apparatus 1 can suitably hold the workpiece 100 and the tool 200 with the workpiece holding section 20 and the tool holding section 30.

[0098] (Example of change) The description of embodiments is illustrative of possible forms of the control device 300 and the gear processing apparatus 1 according to this disclosure, and is not intended to limit such forms. The control device 300 and the gear processing apparatus 1 according to this disclosure may take other forms different from those illustrated in the embodiments, such as the following modifications. The embodiments and the following modifications can be implemented in combination with each other to the extent that they are not technically inconsistent.

[0099] The pre-machined area 110 may be a recess, a through hole, a groove, or a flat surface obtained by machining a substantially cylindrical workpiece 100. In this modified example as well, since the phase of the pre-machined area 110 and the phase of the subsequent machining area 120 are detected, the phase difference d1 between the phase of the pre-machined area 110 and the phase of the subsequent machining area 120 can be appropriately managed. In this modified example, the tool 200 is appropriately selected to form a recess, a through hole, a groove, or a flat surface obtained by machining a substantially cylindrical workpiece 100.

[0100] The leading gear 111 may be an internally geared helical gear, an externally geared spur gear, or an internally geared spur gear. The trailing gear 121 may be an internally geared helical gear, an externally geared spur gear, or an internally geared spur gear.

[0101] The leading gear 111 may be formed above the workpiece 100 than the trailing gear 121. The reference circle radius r1 of the leading gear 111 may be smaller than or equal to the reference circle radius r2 of the trailing gear 121.

[0102] • Tool 200 may be a hob cutter. In this modified example, the workpiece 100 forms a machined portion 101 by hobbing. [Explanation of symbols]

[0103] 1... Gear processing equipment 20...Workpiece holding section 30...Tool holding part 100...work 101…Processing part 110…Preliminary processing area 111…Pre-machined gears 120… Trailing machining area 121... Sequentially machined gears 200...Tools 300...Control device 301... Control Unit 310...Phase detection unit

Claims

1. A control device for a gear machining apparatus, comprising a control unit that controls the synchronous rotation and relative movement between a tool that machines a workpiece and the workpiece, such that a plurality of machined parts are formed on the workpiece, including a pre-machined part and a post-machined gear as a post-machined part, The system includes a phase detection unit that detects the phase of the preceding processed area after the start of processing and before the finishing of the preceding processed area, and detects the phase of the succeeding processed area after the start of processing and before the finishing of the succeeding processed area. Control device.

2. The aforementioned pre-machined portion includes the pre-machined gear, The phase detection unit is After the start of machining of the preceding gear and before the finishing of the preceding gear, the phase of the preceding gear is detected. The phase of the subsequent machining portion is detected after the start of machining of the subsequent machining gear and before the finishing of the subsequent machining gear. The control device according to claim 1.

3. The control unit controls the synchronous rotation and relative movement of the tool and the workpiece so as to reduce the phase difference between the phase of the leading gear and the phase of the trailing gear. The control device according to claim 2.

4. The control unit, if the phase difference is greater than or equal to a predetermined phase difference, will not perform the finishing process on the subsequent gear for which the phase difference was detected. The control device according to claim 3.

5. A control device according to any one of claims 1 to 4, A tool holder that rotatably holds the aforementioned tool, The system includes a workpiece holding section that rotatably holds the workpiece, Gear machining equipment.

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