Processing system

Abstract

Provided is a machining system that can accurately monitor subsequent machining based on an adjusted machining load that is adjusted simply and accurately using adjustment information identified based on an actual machining load. 【Solution means】A simulation unit 12 having a motion step generation unit 44, a machining load estimation unit 38, and a specific cutting resistance storage unit 46 that stores specific cutting resistance corresponding to workpiece information; an adjustment information storage unit 48 that stores adjustment information; an adjustment unit 14 that adjusts the machining load estimated using the adjustment information; a control device 20 that controls a machine device 18 that performs actual machining on a workpiece W and monitors the machining load; a detection unit 32 that detects the actual machining load; a machine tool 16; and an adjustment information identification unit 54 that identifies adjustment information based on the estimated machining load and the actual machining load and stores the adjustment information in the adjustment information storage unit 48 corresponding to the tool information and the workpiece information.

Description

Technical Field

[0001] The present invention relates to a processing system.

Background Art

[0002] When machining a workpiece with a machine tool, it is necessary to monitor whether the generated machining load is appropriate. As a result of the monitoring, if the machining load is higher than the monitoring standard, it is determined that an abnormality has occurred, and the machine is stopped, or the machining load is reduced by lowering the machining conditions from the next time onward to stabilize the machining. On the other hand, when the machining load is lower than the determined monitoring standard, the machining time is shortened by improving the machining conditions from the next time onward. In monitoring machining, since it is preferable to set the monitoring standard in advance prior to actual machining, conventionally, it is determined by estimation using the specific cutting resistance of the nominal value or the like. However, in actual machining, due to variations in the physical property values of the actual workpiece and differences in various specifications such as the clearance angle and rake angle of the tool used for machining, it is often impossible to accurately estimate the machining load.

[0003] Citation Document 1 discloses a computer and a processing method for estimating the specific cutting resistance, which is the cutting force coefficient for each combination of tool and material, based on the shape data of a test piece machined with a test program and improving the accuracy of the estimation. However, in such a processing method, a measurement process and a measuring device for acquiring the shape data of the test piece are separately required, so the man-hours and costs increase.

[0004] Further, the specific cutting resistance is a nominal value. In order to make the accuracy of estimating the machining load closer to the actual situation, it is necessary to actually prepare a machine tool, a tool, and a workpiece and perform actual machining, and identify the specific cutting resistance based on the actual machining load data and CWE (Cutter-Workpiece Engagement) information generated at that time. However, such identification requires a very high computing ability, and it is also necessary to provide a device for directly measuring the machining load or the like on the machine tool, so the man-hours and costs increase.

[0005] Furthermore, in general commercially available software for providing machining simulation, it is common for software vendors to black-box the database area of specific cutting resistance as their own know-how. For this reason, even if a machine tool manufacturer or user who actually performs machining estimates the specific cutting resistance based on actual machining, they cannot access the database area of the specific cutting resistance, and thus the current situation is that the estimation results of the specific cutting resistance cannot be reflected.

Prior Art Documents

Patent Documents

[0006]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0007] In view of the above circumstances, the present invention specifies adjustment information for adjusting an estimated machining load based on an actual machining load when actual machining is performed on a machine tool, and further, based on an adjusted machining load that is simply and accurately adjusted using the adjustment information, aims to provide a machining system capable of accurately monitoring subsequent machining.

Means for Solving the Problems

[0008] According to one aspect of the present invention, there is provided a machining system that executes a machining program in a machine tool and performs machining on a workpiece using a tool, the machining system including: a machine device that performs actual machining on the workpiece based on the machining program; a control device that controls the machine device; a detection unit that detects an actual machining load generated in the machine device corresponding to a motion step obtained by subdividing the machining program and stores the detected load in the control device; a monitoring unit that monitors the actual machining load; a machine tool including the above components; a motion step generation unit that generates motion steps; a machining load estimation unit that estimates, as an estimated machining load, the machining load of the machine device for each motion step when the machining program is executed; a specific cutting resistance storage unit that stores specific cutting resistance used for the estimation in association with workpiece information; a simulation unit including the above components; an adjustment unit that has an adjustment information storage unit that stores adjustment information in association with tool information and workpiece information, and adjusts the estimated machining load using the adjustment information; and an adjustment information specifying unit that specifies adjustment information used for adjusting the estimated machining load based on a comparison between the estimated machining load and the actual machining load, and stores the adjustment information in the adjustment information storage unit in association with the tool information and workpiece information when the actual machining load occurs.

Effect of the Invention

[0009] According to a processing system according to one aspect of the present invention, a simulation unit of the processing system has a motion step generation unit and a processing load estimation unit, and can generate motion steps obtained by subdividing a processing program and estimate the estimated processing load of a machine device of a machine tool for each motion step. Further, an adjustment unit of the processing system has an adjustment information storage unit that stores adjustment information in association with tool information and workpiece information, and can adjust the estimated processing load using the adjustment information. Furthermore, a machine tool of the processing system has a control device, a detection unit, and a monitoring unit that control the machine device. The detection unit can detect an actual processing load generated in the machine device corresponding to a motion step and store it in the control device. In addition, an adjustment information specifying unit of the processing system specifies adjustment information used for adjusting the estimated processing load based on a comparison between the estimated processing load and the actual processing load, and can store the adjustment information in the adjustment information storage unit in association with the tool information and the workpiece information when the actual processing load occurs. Therefore, it is possible to specify adjustment information used for adjusting the estimated processing load based on the actual processing load when actual processing is performed on a machine tool. As a result, it becomes possible to simply and accurately adjust the estimated processing load using the adjustment information, and it is possible to accurately monitor subsequent processing based on the adjusted processing load.

Brief Description of Drawings

[0010]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

DETAILED DESCRIPTION OF THE INVENTION

[0011] Hereinafter, a machining system according to an embodiment will be described with reference to the accompanying drawings. The same or corresponding elements are denoted by the same reference numerals, and redundant descriptions will be omitted. In order to facilitate understanding, the scale of the drawings may be changed for the description.

[0012] FIG. 1 shows a block diagram of a machining system 10 according to the present embodiment. The machining system 10 is a system for executing a machining program (see FIG. 2) in a machine tool 16, operating a tool TL in accordance with the commands of the machining program, and machining a workpiece W. The machining system 10 is configured to detect an actual machining load PL3, which is an actual load that actually occurs during machining, on a machining apparatus 18 that machines the workpiece W, and to be able to estimate in advance an estimated machining load PL1, which is an estimated machining load. Further, the machining system 10 is configured to set a monitoring band BM (see FIG. 6) for the machining load based on the estimated machining load PL1, and to monitor whether the detected actual machining load PL3 exceeds or falls below the monitoring band BM. For this reason, the machining system 10 includes a simulation unit 12 for estimating the estimated machining load PL1, and a machine tool 16 for actually machining the workpiece W (hereinafter referred to as actual machining). The simulation unit 12 is electrically connected to the machine tool 16 and has an adjustment unit 14 for adjusting the estimated machining load PL. Note that the “machining load” in this document means the load generated on the machining apparatus 18 when machining the workpiece W using the tool TL, but depending on the context, it may also be expressed as an “estimated machining load” obtained by estimating the machining load in advance or an “adjusted machining load” obtained by adjusting the estimated machining load. Therefore, the “machining load” is a concept that includes “cutting resistance”, “cutting load”, or “machining resistance”.

[0013] The machine tool 16 includes a machine device 18 that performs actual machining on a workpiece W, and a control device 20 that controls the machine device 18. Here, as an example, the machine device 18 is a horizontal cutting machine. The machine device 18 includes a bed 22 that serves as a base, and a column 24 erected on the upper surface of the bed 22. On the upper surface of the bed 22, a table 28 for fixing the workpiece W, which is the object to be machined, by a fixture (not shown) is arranged. The table 28 is configured to be movable on the bed 22 via a guide surface.

[0014] Machine coordinates with a predetermined position as the origin are preset in the machine device 18, and include an X-axis, a Y-axis, and a Z-axis as linear motion axes orthogonal to each other. Here, the Z-axis extends along the horizontal direction (the left-right direction of the paper surface). Also, the X-axis and the Y-axis are set on a plane perpendicular to the Z-axis, that is, on a vertical plane. In the machine device 18, the column 24 is configured to move along the X-axis direction (the direction perpendicular to the paper surface). Also, a saddle (not shown) is arranged on the front surface of the column 24 and is configured to be movable along the Y-axis direction (the up-down direction of the paper surface).

[0015] A spindle head (not shown) is arranged on the front surface of the saddle of the machine device 18, and a spindle 26 configured to be rotatable around an axis parallel to the Z-axis is attached to the tip side of the spindle head. A tool TL for machining the workpiece W while rotating together with the spindle 26 is detachably attached to the spindle 26. The machine device 18 is configured such that the spindle 26 for attaching the tool TL and the table 28 for arranging the workpiece W are relatively movable along the X-axis, the Y-axis, and the Z-axis.

[0016] The machine device 18 also has a tool changer 30 in order to perform various types of machining according to the machining purpose, and the tool changer 30 is configured to be able to exchange the tool TL attached to the spindle 26. Further, the machine device 18 includes a detection unit 32 configured to calculate (detect) an actual machining load PL3 from the load generated in a motor (not shown) that drives the spindle 26 and motors that drive a linear motion mechanism and a rotation mechanism (not shown) that relatively move the spindle and the table.

[0017] The machining system 10 includes a CAM (Computer Aided Manufacturing) system 34 for generating a machining program (see FIG. 2) based on information of a workpiece W to be machined. An operator of the machining system 10 inputs information necessary for machining, such as model data regarding the workpiece W, workpiece material information, and workpiece model number information, into the CAM system 34 to generate a machining program. Here, information necessary for machining may further include information of a jig (not shown) for attaching the workpiece W for the purpose of performing detailed interference confirmation between the tool TL and the workpiece W. When the CAM system 34 generates a machining program, it transmits (inputs) the machining program to the simulation unit 12 together with model data of the workpiece W and the like. Note that, without going through the CAM system 34, an operator may directly create a machining program based on experience and input it into the simulation unit 12.

[0018] The simulation unit 12 performs simulation of the machining program. For this purpose, the simulation unit 12 has an interference confirmation unit 36 and a motion step generation unit 44. The motion step generation unit 44 generates motion steps obtained by subdividing the content of the machining program. FIG. 2 shows an example of a machining program (program number: O3001). Here, motion steps are generated each time the linear movement distance in the machining program changes by a certain amount. Note that, hereinafter, it will be described that motion steps are generated based on the linear movement distance, but it is not limited thereto. For example, motion steps may be generated based on the elapsed time in the simulation.

[0019] FIG. 3 shows an example of a data file that records motion steps (columns DF0 to DF7 in FIG. 3) generated along a machining program and various machining loads (columns DF8 to DF10 in FIG. 3). The simulation unit 12 records the generated motion steps in the data file. In the data file, for each subdivided motion step (for each serial number in column DF0 in FIG. 3), a program number (column DF1 in FIG. 3), a corresponding sequence number in the machining program (column DF2 in FIG. 3), a tool number of the tool TL used for machining (column DF3 in FIG. 3), and the material of the workpiece W being machined (column DF4 in FIG. 3) are recorded. Also, the X coordinate (column DF5 in FIG. 3), Y coordinate (column DF6 in FIG. 3), and Z coordinate (column DF7 in FIG. 3) of the tool TL that linearly moves based on the machining program are recorded in the data file. Here, as an example, motion steps are generated every 0.2 mm of linear movement distance.

[0020] In addition, the interference confirmation unit 36 generates interference information (CWE: Cutter-Workpiece Engagement) between the tool TL and the workpiece W based on the machining program and the model information in accordance with the generation of the motion steps. Based on this interference information, the cutting area of the tool TL in each motion step can be calculated.

[0021] The simulation unit 12 further includes a machining load estimation unit 38 and a specific cutting resistance storage unit 46, and uses these to estimate the estimated machining load PL1 simultaneously with the generation of the motion step. When estimating the machining load as the estimated machining load PL1, the machining load estimation unit 38 estimates the machining load (estimated machining load PL1) for each motion step based on the specific cutting resistance stored in the specific cutting resistance storage unit 46 and the cutting area of the tool TL calculated by the interference confirmation unit 36. FIG. 4 shows an example of the specific cutting resistance stored in the specific cutting resistance storage unit 46. Here, the specific cutting resistance is stored for each workpiece W, and the specific cutting resistance corresponding to the workpiece W to be machined is used for the estimation of the estimated machining load PL1. In this way, the estimated machining load PL1 is recorded in the data file (column DF8 in FIG. 3) corresponding to the motion step. Here, the specific cutting resistance is described as a value defined for each material of the workpiece W as shown in FIG. 4, but is not limited thereto, and the specific cutting resistance may be defined for, for example, a plurality of parameters such as the tool as well.

[0022] When a motion step is generated and the machining load estimation unit 38 estimates the estimated machining load PL1, the adjustment unit 14 adjusts the estimated machining information PL1. The adjustment unit 14 internally has an adjustment information storage unit 48 in which adjustment information a for each combination of the tool TL and the workpiece W in the generated motion step is stored (recorded). Here, as information corresponding to the adjustment information a, the tool number of the tool TL and the workpiece material of the workpiece W are stored. FIG. 5 shows an example of the adjustment information a stored in the adjustment information storage unit 48. The adjustment information a (*** in FIG. 5) is recorded for each tool TL (tool number) and workpiece W, and for combinations of tool TL and workpiece W for which the adjustment information a is not specified, it is recorded that there is no adjustment information a (-(none) in FIG. 5). The adjustment unit 14 refers to whether the adjustment information a corresponding to the combination of the tool TL and the workpiece W used in the actual machining is stored, and if it is stored, adjusts the estimated machining load PL1 based on the adjustment information a. Here, the adjusted machining load PL2 is calculated by multiplying the estimated machining load PL1 by the adjustment information a. The calculated adjusted machining load PL2 is recorded in a data file (column DF9 in FIG. 3), and the estimated machining load PL1 in the motion step in which the adjusted machining load PL2 is recorded is deleted. Note that if the adjustment information a is not stored, no adjustment is performed in that motion step, and the estimated machining load PL1 remains recorded in the data file.

[0023] The adjustment information a may be, for example, a coefficient. Specifically, by comparing the estimated machining load PL1 and the actual machining load in time series, in the time series of actual machining, one coefficient that can approximate the greatest common divisor with the actual machining load by multiplying the estimated machining load PL1 can be used as the adjustment information a.

[0024] Here, the adjustment unit 14 is configured separately in area from the machining load estimation unit 38 and the specific cutting resistance storage unit 46 inside the simulation unit 12. Thereby, the processing system 10 can be configured while concealing the calculation models and know-how of the software vendor and the machine tool manufacturer from each other.

[0025] FIG. 6 shows the adjustment machining load PL2 calculated for each motion step. The adjustment unit 14 sets upper and lower limits based on the adjustment machining load PL2 and determines the monitoring band BM. The monitoring band BM calculates the upper limit value UV and the lower limit value LV of the monitoring band BM by adding and subtracting a predetermined ratio (for example, ±5%) preset and stored with respect to the adjustment machining load PL2. The difference between this upper limit value UV and the lower limit value LV is the bandwidth of the monitoring band BM. Note that the monitoring band may be set wider within a range where the load that can be tolerated due to the characteristics of the machine device 18 is not reached.

[0026] When the generation of the motion step and the adjustment of the adjustment machining load PL2 are completed, the simulation unit 12 inputs the machining program (FIG. 2) and the data file (FIG. 3) to the control device 20 of the machine tool 16. The control device 20 operates the machine device 18 based on the input machining program to perform actual machining of the workpiece W. A monitoring unit 52 is arranged in the control device 20, and the actual machining in the machine device 18 can be monitored by checking whether the actual machining load PL3 detected by the detection unit 32 is within the monitoring band BM. The control device 20 also has a machining load storage unit 50, and the actual machining load PL3 detected by the detection unit 32 in actual machining is stored in the machining load storage unit 50 as the past machining load PL4. Also, the actual machining load PL3 is recorded in the data file (column DF10 in FIG. 3).

[0027] Here, when estimating the estimated machining load PL1 using the nominal value kc for the specific cutting resistance, the actual machining load PL3 may deviate from the monitoring band BM set based on the estimated machining load PL1, and the monitoring may not be established. For example, depending on the manufacturing method when casting the workpiece W, variations occur in the physical property values of the actual workpiece W, so the value of the specific cutting resistance of the workpiece W in a specific manufacturer does not necessarily match the nominal value kc. Also, the actual machining load PL3 can vary depending on various cutting edge shapes such as the edge treatment, rake angle, and relief angle of the cutting tool TL used in machining. Thus, due to various factors, there may be cases where the estimated machining load PL1 cannot be accurately estimated. That is, even if the actual machining load PL3 is an appropriate machining load, the monitoring does not hold because it becomes greater than the upper limit value UV of the monitoring band BM based on the incorrectly estimated estimated machining load PL1, or smaller than the lower limit value LV. When the control device 20 is configured to determine that an abnormality has occurred in the mechanical device 18 and stop the mechanical device 18, if the actual machining load PL3 monitored by the monitoring unit 52 is greater than the upper limit value UV or smaller than the lower limit value LV, the mechanical device 18 stops unnecessarily, resulting in a decrease in production efficiency.

[0028] In order to suppress the occurrence of such problems, the machining system 10 according to the present embodiment includes an adjustment information specifying unit 54 in the control device 20, and can specify adjustment information a for comparing the adjusted machining load PL2 and the actual machining load PL3. Here, the adjustment information a is specified so that the adjusted machining load PL2 obtained by multiplying the estimated machining load PL1 by the adjustment information a can be compared with the actual machining load PL3. The specified adjustment information a is stored in the adjustment information storage unit 48 together with the information on the cutting tool TL and the workpiece W. When there is no adjustment information a before actual machining, as in the motion step corresponding to the sequence number N1303 of the data file in FIG. 3, the adjustment information a is specified so that the actual machining load PL3 (the portion surrounded by the square in column DF10 in FIG. 3) and the adjusted machining load PL2 calculated by multiplying the estimated machining load PL1 by the adjustment information a can be adjusted.

[0029] Although it is preferable to detect the actual machining load PL3 for specifying the adjustment information a when irregularities such as casting defects of the workpiece W, clogging of chips, and breakage of the tool TL do not occur, in reality, these irregularities may occur. In this case, the actual machining load PL3 can vary depending on the degree of irregularity. For example, when chip clogging occurs, the actual machining load PL increases, and when the machining allowance decreases due to casting defects of the workpiece W or when there is tool breakage and the tool TL is not in contact with the workpiece W, the actual machining load PL3 decreases. The adjustment information specifying unit 54 of the machining system 10 is configured to be able to specify the adjustment information a after performing actual machining a plurality of times in order to suppress the influence of such irregularities. Therefore, the noise when irregularities occur can be removed, and the adjustment information a can be specified accurately.

[0030] The control device 20 of the machine tool 16 is configured to automatically remove noise from the corresponding plurality of actual machining loads PL3 after the machine device 18 has performed actual machining a plurality of times. Further, the plurality of actual machining loads PL3 can be displayed on a display device (not shown) of the machine tool 16 in a time-series graph, and the operator can visually determine and remove the noise. After removing the noise in this way, the adjustment information a can be specified from the average value of the plurality of actual machining loads PL3. Also, when actual machining is performed a plurality of times and no irregularities occur, that is, when the control device of the machine tool determines that a stable actual machining load PL3 has been obtained, the noise removal process may be omitted, and the adjustment information a may be specified from the average value of the plurality of actual machining loads PL3. Further, when the operator visually determines that irregularities continue to occur in a plurality of actual machinings, it is determined that the actual machining is being performed in an unfavorable state, and the data of the actual machining loads PL3 corresponding to the plurality of actual machinings up to that point are discarded. It is also possible to instruct the machine tool 16 to inspect and review the elements of the actual machining, such as machining conditions, tool TL, jigs, and the state of the machine device 18, and then perform the actual machining a plurality of times again.

[0031] The simulation unit 12 may also include an optimization unit 40 and a machine information storage unit 42. When the estimated processing load PL1 or the adjusted processing load PL2 exceeds the allowable processing load stored in the machine information storage unit 42, the optimization unit 40 is configured to slow down the processing speed in the processing program so as not to exceed the allowable processing load. Further, when the estimated processing load PL1 or the adjusted processing load PL2 is below the allowable processing load, the optimization unit 40 is configured to increase the processing speed in the processing program within a range not exceeding the allowable processing load. Also, in either case where the estimated processing load PL1 exceeds or is below the allowable processing load, the processing program can be returned to the CAM system 34 or the operator without automatic optimization. Since these optimizations are performed based on the estimated processing load PL1 or the adjusted processing load PL2, accurately adjusting the processing load is also important in optimization. Further, when the interference confirmation unit 36 confirms the interference of the workpiece W, the tool TL, and the machine device 18 when the processing program is executed, the simulation unit 12 can return to the program generation process, that is, the CAM system 34 or the operator.

[0032] Through the description of the processing process of the workpiece W using the flowchart of the processing system 10 shown in FIG. 7, the operation and effect of the processing system 10 according to the present embodiment will be described below.

[0033] First, it proceeds to step S10 to start the processing process, and then proceeds to step S20 where the CAM system 34 generates a processing program. Next, it proceeds to step S30, and the CAM system 34 inputs the processing program and the model data to the simulation unit 12.

[0034] Furthermore, it proceeds to step S40, where the motion step generation unit 44 generates motion steps one by one based on the machining program, and at the same time, the machining load estimation unit 38 estimates the estimated machining load PL1 using the specific cutting resistance stored in the specific cutting resistance storage unit 46. Next, it proceeds to step S50 to check whether adjustment information a corresponding to the tool TL used in the motion step and the workpiece W to be actually machined exists in the adjustment information storage unit 48. If the adjustment information a exists, it proceeds to step S60, multiplies the estimated machining load PL1 by the adjustment information a to adjust it to the adjusted machining load PL2, and deletes the estimated machining load PL1 from the data file. Subsequently, it proceeds to step S70 to check whether the generation of all the motion steps of the machining program is completed. Thereafter, steps S40 to S70 are repeated until the generation of all the motion steps is completed.

[0035] Also, in step S50, if the adjustment information a does not exist, no adjustment is made and the estimated machining load PL1 is left recorded. Subsequently, it proceeds to step S70 to check whether the generation of all the motion steps of the machining program is completed. Thereafter, steps S40 to S70 are repeated until the generation of all the motion steps is completed.

[0036] When the generation of all the motion steps is completed, it proceeds to step S80, where the simulation unit 12 inputs the machining program and the data file to the control device 20 of the machine tool 16. Furthermore, it proceeds to step S90, and based on the command from the control device 20, the mechanical device 18 starts actual machining along the machining program. When the actual machining starts, it proceeds to step S100. When executing the machining program, the control device 20 checks whether the past machining load PL4 corresponding to the combination information of the nth tool TL and the workpiece W is stored in the machining load storage unit 50.

[0037] When the past processing load PL4 corresponding to the combination information of the tool TL and the workpiece W is stored in the processing load storage unit 50, the process proceeds to step S110. During the processing of the n-th tool TL, the monitoring unit 52 monitors the actual processing load PL3 based on the past processing load PL4 (Case X in FIG. 7). Here, the machine tool 16 stores the actual processing load PL3 in the processing load storage unit 50 during actual processing, and can use it as the past processing load PL4 for monitoring the actual processing of the same combination of the tool TL and the workpiece W in subsequent times. By using the past processing load PL4, the reliability of the monitoring band BM can be increased compared to the monitoring band BM based on the estimated processing load PL1 and the adjusted processing load PL2, so that accurate monitoring can be performed. When the actual processing and its monitoring of the n-th tool TL are completed, the process proceeds to step S120 to confirm whether the processing using all the tools TL is completed. The flow between step S100 and step S120 is repeated until the processing using all the tools TL is completed. Note that when storing the past processing load PL4, the processing load storage unit 50 can also store the processing program number and the sequence number group in addition to the combination information of the tool TL and the workpiece W. The monitoring unit 52 can correctly refer to the past processing load PL4 for the actual processing load PL3.

[0038] Also, in step S100, when the past processing load PL4 corresponding to the combination information of the tool TL and the workpiece W is not stored in the processing load storage unit 50 for the n-th tool TL, the process proceeds to step S130.

[0039] When shifting to step S130, it is checked whether the estimated machining load PL1 for the n-th tool TL of the machining program has been adjusted, that is, whether the adjusted machining load PL2 is recorded in the data file. When the adjusted machining load PL2 is stored in the adjustment information storage unit 48, the process proceeds to step S140. During actual machining using the n-th tool TL, the monitoring unit 52 monitors the actual machining load PL3 based on the adjusted machining load PL2. At the same time, the control device 20 stores the actual machining load PL3 in the machining load storage unit 50 (Case Y in FIG. 7). The adjusted machining load PL2 is adjusted based on the adjustment information a specified based on the actual machining load PL3 and is more reliable information than the estimated machining load PL1, so the monitoring accuracy of machining can be improved. Also, the actual machining load PL3 at this time is stored in the machining load storage unit 50 and can be used for monitoring machining as the past machining load PL4 in subsequent machining. When the actual machining load PL3 is stored in the machining load storage unit 50, the process proceeds to step S120 to check whether machining using all the tools TL has been completed. Until machining using all the tools TL is completed, the flow between step S100 and step S120 is repeated.

[0040] In this Case Y, although the past machining load PL4 is not stored because the machine tool 16 has not been used for machining, cases where the adjustment information a has been specified may be included because machining has been performed using the same combination of tool TL and workpiece W on other machine tools 16. Also, even when the adjustment information a has been specified because a different shape has been machined using the same combination of tool TL and workpiece W on the machine tool 16, but this is the first time machining is being performed according to the input machining program, it may be included in Case Y.

[0041] When the adjustment processing load PL2 is not stored in the adjustment information storage unit 48, the process proceeds to step S150. During the processing using the nth tool TL, the monitoring unit 52 monitors the actual processing load PL3 based on the estimated processing load PL1, and the processing load storage unit 50 stores the actual processing load PL3 (case Z in the figure). Therefore, the actual processing load PL3 stored in the processing load storage unit 50 can also be used for monitoring the processing as the past processing load PL4 in the actual processing after the next time. Further, the process proceeds to step S160, and the adjustment information specifying unit 54 specifies the adjustment information a based on the actual processing load PL3 and the estimated processing load PL1, and updates the adjustment information storage unit 48. Specifically, the adjustment information a is specified based on the difference between the estimated processing load PL1 and the actual processing load PL3, and is stored in the adjustment information storage unit 48 in association with the combination information of the tool TL and the workpiece W. Then, the process proceeds to step S120 to check whether the processing using all the tools TL has been completed. The flow between step S100 and step S120 is repeated until the processing using all the tools TL is completed.

[0042] When the control device 20 proceeds to step S150, it detects the elapse of a predetermined time after the start of the actual processing, determines the temporary adjustment information a based on the comparison between the actual processing load PL3 acquired by this elapsed time and the corresponding estimated processing load PL1, and is configured to be able to calculate the adjustment processing load PL2 with this temporary adjustment information a. Also, in this case, after the elapse of the predetermined time, monitoring can be performed based on the adjustment processing load PL2 calculated with the temporary adjustment information a. Note that the detection of the elapse of the predetermined time may be made by the judgment of the operator instead of the control device 20. The control device 20 is provided with settings for acquiring such temporary adjustment information a, and when the operator presses the temporary adjustment button displayed on the display unit (not shown) of the control device 20 during processing, the temporary adjustment information a can be determined based on the actual processing load PL3 acquired up to that point and the corresponding estimated processing load PL1.

[0043] According to the processing system 10 according to one aspect of the present invention, the simulation unit 12 has a motion step generation unit 44 and a processing load estimation unit 38, and can generate motion steps obtained by subdividing a processing program, and estimate the processing load generated in the machine device 18 of the machine tool 16 for each motion step. Further, the adjustment unit 14 has an adjustment information storage unit 48 that stores adjustment information a in correspondence with tool information and workpiece information, and can adjust the estimated processing load PL1 using the adjustment information a to calculate an adjusted processing load PL2. Since the adjusted processing load PL2 is adjusted based on the adjustment information a specified based on the actual processing load PL3, it can be information more reliable than the estimated processing load PL1, so that processing can be monitored with improved accuracy.

[0044] Furthermore, according to the processing system 10 according to one aspect of the present invention, the machine tool 16 has a control device 20 that controls the machine device 18, a detection unit 32, and a monitoring unit 52. The detection unit 32 can detect the actual processing load PL3 generated in the machine device 18 corresponding to the motion step and store it in the control device 20. Therefore, the actual processing load PL3 stored in the processing load storage unit 50 can be used as the past processing load PL4 in subsequent processing for monitoring the processing.

[0045] Also, according to the processing system 10 according to one aspect of the present invention, the adjustment information specifying unit 54 specifies the adjustment information a used for adjusting the estimated processing load PL1 based on the comparison between the estimated processing load PL1 and the actual processing load PL3, and can store the adjustment information a in the adjustment information storage unit 48 in correspondence with the tool information and workpiece information when the actual processing load PL3 occurs. Therefore, based on the actual processing load PL3 when actual processing is performed on the machine tool 16, the adjustment information a used for adjusting the estimated processing load PL1 can be specified. As a result, the estimated processing load PL1 can be simply and accurately adjusted using the adjustment information a, that is, the adjusted processing load PL2 can be calculated, and subsequent processing can be accurately monitored using the adjusted processing load PL2.

[0046] Furthermore, according to the processing system 10 according to one aspect of the present invention, the adjustment information specifying unit 54 of the processing system 10 is configured to be able to specify adjustment information a after performing actual processing a plurality of times in order to suppress the influence of irregularities caused by casting defects of the workpiece W, clogging of chips, breakage of the tool TL, etc. For this reason, noise at the time of occurrence of irregularities can be removed, and the adjustment information a can be specified accurately.

[0047] Also, according to the processing system 10 according to one aspect of the present invention, since it is not necessary to specify the specific cutting resistance, the simulation unit 12 of the processing system 10 does not require a high computing ability or a special processing load measuring device. For this reason, the simulation unit 12 can be configured at low cost. Furthermore, the adjustment unit 14 is configured with a separate area from at least the processing load estimation unit 38 and the specific cutting resistance storage unit 46 inside the simulation unit 12. As a result, the processing system 10 can be configured while concealing the calculation models and know-how of the software vendor and the machine tool manufacturer from each other.

[0048] As described above, the processing system 10 according to the present embodiment specifies adjustment information for comparing the estimated processing load and the actual processing load based on the actual processing load when performing actual processing on a machine tool, and further, simply and accurately adjusts the processing load estimated using the adjustment information. As a result, subsequent processing can be monitored accurately.

[0049] Here, the adjustment unit 14 has been described as being configured inside the simulation unit 12, but the present invention is not limited to this, and it may be configured independently of the simulation unit or may be configured inside the machine tool.

[0050] Although the embodiments of the processing system 10 have been described above, the present invention is not limited to the above embodiments. For example, instead of a vertical machining center with a horizontal spindle orientation, a horizontal machining center with a vertical spindle orientation may be used. Machining centers other than the machining center 16 may be included in the processing system 10. In addition to the above, those skilled in the art can understand that various modifications of the above embodiments are possible.

Explanation of Reference Numerals

[0051] 10 Processing system 12 Simulation unit 14 Adjustment unit 16 Machining center 18 Machine device 20 Control device 32 Detection unit 38 Machining load estimation unit 44 Motion step generation unit 46 Specific cutting resistance storage unit 48 Adjustment information storage unit 54 Adjustment information specifying unit a Adjustment information PL1 Estimated machining load PL3 Actual machining load TL Tool W Workpiece

Claims

1. A machining system that executes a machining program in a machine tool and performs machining on a workpiece using a tool, comprising: a machine device that performs actual machining on a workpiece based on the machining program; a control device that controls the machine device; a detection unit that detects an actual machining load generated in the machine device corresponding to a motion step obtained by subdividing the machining program and stores the detected load in the control device; and a monitoring unit that monitors the actual machining load; a simulation unit including a motion step generation unit that generates the motion step, a machining load estimation unit that estimates the machining load of the machine device for each motion step when the machining program is executed as an estimated machining load, and a specific cutting resistance storage unit that stores the specific cutting resistance used for the estimation in association with workpiece information; an adjustment unit that has an adjustment information storage unit that stores adjustment information in association with tool information and workpiece information, and that adjusts the estimated machining load using the adjustment information; an adjustment information specifying unit that specifies adjustment information used for adjusting the estimated machining load based on a comparison between the estimated machining load and the actual machining load, and stores the adjustment information in the adjustment information storage unit in association with the tool information and workpiece information when the actual machining load occurs; A machining system comprising the above components.

2. The machining system according to claim 1, wherein the machine tool performs the actual machining a plurality of times, and the adjustment information specifying unit specifies the adjustment information based on a plurality of actual machining loads corresponding to the plurality of actual machinings.

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