Metal material processing apparatus and metal material processing method

Abstract

To provide a metal material processing device and a metal material processing method that can automatically and accurately process a processing surface of a metal material.SOLUTION: A metal material processing device includes: a processing unit which has scraping means for scraping a metal material; a movement mechanism which moves the processing unit; a first sensor which is fixed to the processing unit and measures the first relative distance to a processing surface on the metal material; a second sensor which measures the second relative distance to the scraping means; and a control unit which adjusts the position of the scraping means by controlling the movement mechanism on the basis of the first and second relative distances so that the lowest point of the scraping means is not located below the processing surface while bringing the scraping means into contact with a convex part on the processing surface.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to a metal material processing apparatus and a metal material processing method.

Background Art

[0002] Conventionally, welding for joining two or more metal materials has been widely performed (for example, see Patent Document 1). A convex portion (so-called bead) is formed at the joint of the metal materials. Such a convex portion is removed after the welding process, for example, by an operator processing the surface (processing surface) of the metal material with a file or the like.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] By the way, it is desirable that the processing of the surface (processing surface) of the above-mentioned metal material be performed with high precision. Further, from the viewpoint of improving work efficiency and the like, it is desirable that such processing can be executed by automatic control using a robot or the like.

[0005] The present invention has been made in consideration of such circumstances, and an object thereof is to provide a metal material processing apparatus and a metal material processing method capable of automatically and accurately processing the processing surface of a metal material.

Means for Solving the Problems

[0006] In order to solve the above problems, a metal material processing apparatus according to Aspect 1 of the present invention includes a cutting means for cutting a metal material, a processing unit having the cutting means for cutting the metal material, a moving mechanism for moving the processing unit, a first sensor fixed to the processing unit for measuring a first relative distance to a processing surface on the metal material, a second sensor for measuring a second relative distance to the cutting means, and a control unit for controlling the moving mechanism based on the first relative distance and the second relative distance to adjust the position of the cutting means so that the lowest point of the cutting means does not lie below the processing surface while bringing the cutting means into contact with a convex portion on the processing surface.

[0007] According to Aspect 1 of the present invention, it is possible to prevent over-cutting of the processing surface by the cutting means. Thereby, the processing of the processing surface can be performed with high accuracy. In addition, the processing of the processing surface can be automated by the processing of the control unit.

[0008] Further, in Aspect 2 of the present invention, in the metal material processing apparatus of Aspect 1, the cutting means floats by a pressing force received from the metal material.

[0009] Further, in Aspect 3 of the present invention, in the metal material processing apparatus of Aspect 1 or Aspect 2, the processing unit has a rotating mechanism for rotating the cutting means, the second sensor measures a change in the second relative distance when the cutting means is rotated, and the control unit adjusts the position of the cutting means based on the minimum value of the second relative distance.

[0010] Further, in Aspect 4 of the present invention, in the metal material processing apparatus according to any one of Aspects 1 to 3, the second sensor measures the second relative distance a plurality of times at predetermined time intervals, and the control unit adjusts the position of the cutting means based on the second relative distance each time the second relative distance is measured.

[0011] In order to solve the above problems, the metal material processing method according to aspect 5 of the present invention uses a metal material processing apparatus including a processing unit having a cutting means for polishing a metal material, a moving mechanism for moving the processing unit, a first sensor fixed to the processing unit for measuring a first relative distance to a processing surface on the metal material, a second sensor for measuring a second relative distance to the cutting means, and a control unit, and includes a first measurement step in which the first sensor measures the first relative distance, a second measurement step in which the second sensor measures the second relative distance, and an adjustment processing step in which the control unit controls the moving mechanism based on the first relative distance and the second relative distance to adjust the position of the cutting means so that the lowest point of the cutting means does not lie below the processing surface while bringing the cutting means into contact with a convex portion on the processing surface.

[0012] According to aspect 5 of the present invention, it is possible to prevent over-cutting of the processing surface by the cutting means. Thereby, the processing of the processing surface can be performed with high accuracy. In addition, the processing of the processing surface can be automated by the processing of the control unit.

[0013] Further, aspect 6 of the present invention is the metal material processing method according to aspect 5, in which in the second measurement step, the second sensor measures a change in the second relative distance while rotating the cutting means, and in the adjustment processing step, the control unit adjusts the position of the cutting means based on the minimum value of the second relative distance.

[0014] Further, aspect 7 of the present invention is the metal material processing method according to aspect 5 or aspect 6, in which the second measurement step and the adjustment processing step are repeated a plurality of times at predetermined time intervals.

Effects of the Invention

[0015] According to the above aspects of the present invention, it is possible to provide a metal material processing apparatus and a metal material processing method capable of automatically and accurately processing a processing surface of a metal material.

Brief Description of the Drawings

[0016]

Figure 1

Figure 2

Figure 3

Figure 4A

Figure 4B

Figure 4C

Figure 4D

Mode for Carrying Out the Invention

[0017] (Metal Material Processing Apparatus) Hereinafter, a metal material processing apparatus according to an embodiment of the present invention will be described with reference to the drawings.

[0018] As shown in FIG. 1, a processing apparatus (metal material processing apparatus) 1 according to the present embodiment includes a processing unit 10, a main body unit 11, a moving mechanism 13, a control unit 16, a first sensor 21, and a second sensor 22. The processing unit 10 has a cutting means 12, a rotating mechanism 14, and a floating detection unit 15. The cutting means 12 is arranged to face the surface (machining surface 30s) of the workpiece 30. The moving mechanism 13 is, for example, a robot.

[0019] The processing apparatus 1 is an apparatus for processing the machining surface 30s of a metal workpiece (metal material) 30. More specifically, the processing apparatus 1 is an apparatus that removes a convex portion 31 on the machining surface 30s by cutting with the cutting means 12 and processes the machining surface 30s into a desired shape. The convex portion 31 is, for example, a bead generated when two or more metal materials are welded.

[0020] [[ID=3)]] Hereinafter, the direction intersecting (for example, orthogonal) to the machining surface 30s is referred to as the vertical direction Z. One direction intersecting (for example, orthogonal) to the vertical direction Z is referred to as the first direction X. The direction intersecting (for example, orthogonal) to both the vertical direction Z and the first direction X is referred to as the second direction Y. The first direction X and the second direction Y are also directions along the machining surface 30s. Further, along the vertical direction Z, the direction from the workpiece 30 toward the machining portion 10 is referred to as upward and is represented by the +Z direction. The direction opposite to the +Z direction is referred to as downward and is represented by the -Z direction. Also, the two directions along the first direction X are represented by the +X direction and the -X direction, respectively. The two directions along the second direction Y are represented by the -Y direction and the +Y direction, respectively. Further, hereinafter, the position in the vertical direction Z may be simply referred to as "height".

[0021] The main body portion 11 supports the moving mechanism 13. The main body portion 11 is, for example, the housing of a robot.

[0022] The cutting means 12 is means for cutting and removing the convex portion 31 on the machining surface 30s. The cutting means 12 removes the convex portion 31, for example, by polishing or grinding the convex portion 31. The cutting means 12 is, for example, a grinder for grinding the convex portion 31 or a sander for polishing the convex portion 31. The cutting means 12 according to the present embodiment has a shaft portion 12a and a rotary cutting portion 12b.

[0023] The shaft portion 12a is a portion that extends linearly from the rotation mechanism 14. The rotary cutting portion 12b is fixed to the tip of the shaft portion 12a. The rotary cutting portion 12b has, for example, a circular shape in a plan view (when viewed from the vertical direction Z). Abrasive grains for contacting the convex portion 31 and cutting (polishing or grinding) the convex portion 31 are provided on the lower surface of the rotary cutting portion 12b. The shaft portion 12a and the rotary cutting portion 12b are configured to be rotatable about the central axis O of the cutting means 12. The central axis O extends along the shaft portion 12a. The rotation of the shaft portion 12a and the rotary cutting portion 12b is driven, for example, by the rotation mechanism 14. When the lower surface of the rotary cutting portion 12b contacts the convex portion 31 in a state where the rotary cutting portion 12b is rotating, the convex portion 31 is cut, and the convex portion 31 is removed from the machining surface 30s. The cutting means 12 is configured to apply a load of, for example, about several grams to the convex portion 31.

[0024] The cutting means 12 according to the present embodiment has a floating mechanism (floating detection unit 15) that floats by a pressing force received from the workpiece 30 or the like. That is, in a state where no external force is applied, the rotary cutting portion 12b is located at a predetermined natural position. Then, when a pressing force (for example, about several grams) directed upward from the lower surface of the rotary cutting portion 12b is received, the rotary cutting portion 12b floats upward from the natural position due to the pressing force. Then, when the application of such a pressing force is released, the cutting means 12 descends and returns to the natural position. Also, the cutting means 12 is configured not to descend below the natural position.

[0025] The moving mechanism 13 moves the cutting means 12 by moving the machining unit 10, for example, based on an instruction from the control unit 16. More specifically, the moving mechanism 13 moves the cutting means 12 in the first direction X, the second direction Y, and the vertical direction Z. In other words, the moving mechanism 13 changes the relative position of the cutting means 12 with respect to the workpiece 30 (machining surface 30s) in the first direction X, the second direction Y, and the vertical direction Z.

[0026] Further, the moving mechanism 13 may have a function as a tilting mechanism that tilts the cutting means 12 with respect to the workpiece 30 (machined surface 30s). Note that when it is not necessary to tilt the cutting means 12 with respect to the machined surface 30s, etc., the moving mechanism 13 may not have a function as a tilting mechanism that tilts the cutting means 12 with respect to the machined surface 30s. The moving mechanism 13 may be able to tilt the cutting means 12 in a plurality of directions (for example, three directions) with respect to the workpiece 30.

[0027] The rotation mechanism 14 rotates the cutting means 12 (shaft portion 12a and rotary cutting portion 12b) around the central axis O of the cutting means 12, for example, based on an instruction from the control unit 16.

[0028] The floating detection unit 15 detects the floating amount of the cutting means 12. Note that the "floating amount of the cutting means 12" is an amount indicating how much the cutting means 12 has floated from the natural position of the rotary cutting portion 12b. When the rotary cutting portion 12b is in the natural position, the floating amount of the cutting means 12 is 0 (zero). The floating detection unit 15 outputs the detected floating amount of the cutting means 12 to the control unit 16.

[0029] The control unit 16 comprehensively controls the operation of the processing unit 10. For example, the control unit 16 controls the moving mechanism 13 based on the first relative distance L1 and the second relative distance L2 described later, and adjusts the position of the cutting means 12. More specifically, the control unit 16 controls the moving mechanism 13 so that the lowermost point P of the cutting means 12 (rotary cutting portion 12b) is not located below the machined surface 30s while bringing the cutting means 12 (rotary cutting portion 12b) into contact with the convex portion 31 on the machined surface 30s. The control unit 16 may have a storage unit that stores the outputs of the floating detection unit 15 and the sensors 21 and 22. Alternatively, the processing apparatus 1 may be provided with the above-described storage unit separately from the control unit 16, and may be configured such that the control unit 16 can refer to the information stored in the storage unit.

[0030] The first sensor 21 is fixed to the lower surface of the floating detection unit 15. The first sensor 21 measures the distance from the first sensor 21 to the machining surface 30s (hereinafter referred to as the first relative distance L1). More specifically, the first relative distance L1 is the distance between the first sensor 21 and the machining surface 30s in the vertical direction Z. In the illustrated example, the first sensor 21 measures the first relative distance L1 by measuring the distance to a reference surface 30s' arranged on the same plane as the machining surface 30s. The first sensor 21 is, for example, a laser sensor. However, the type of the first sensor 21 is not particularly limited as long as it can measure the first relative distance L1 and can be changed as appropriate. The first sensor 21 outputs the measured first relative distance L1 to the control unit 16.

[0031] The second sensor 22 is fixed to the measuring jig 30' having the reference surface 30s'. The second sensor 22 measures the distance from the second sensor 22 to the cutting means 12 (rotary cutting part 12b) (hereinafter referred to as the second relative distance L2). More specifically, the second relative distance L2 is the distance between the second sensor 22 and the cutting means 12 (rotary cutting part 12b) in the vertical direction Z. The second sensor 22 may measure the second relative distance L2 in a range from the outer circumference of the rotary cutting part 12b to about 1 mm inside the diameter. The second sensor 22 is, for example, a laser sensor. However, the type of the second sensor 22 is not particularly limited as long as it can measure the second relative distance L2 and can be changed as appropriate. The second sensor 22 outputs the measured second relative distance L2 to the control unit 16.

[0032] In the illustrated example, by temporarily arranging the auxiliary plate 32 for comparison on the reference surface 30s', the second sensor 22 is configured to be able to measure the distance equivalent to the machining surface 30s from the second sensor 22 (hereinafter referred to as the measurement reference distance L3). In the illustrated example, the auxiliary plate 32 is arranged to protrude in the in-plane direction of the reference surface 30s' from the reference surface 30s' so that at least a part of the auxiliary plate 32 faces the second sensor 22 in the vertical direction Z. Then, the second sensor 22 measures the measurement reference distance L3 by measuring the distance to the lower surface of the auxiliary plate 32. The measured measurement reference distance L3 and the first relative distance L1 are output to and recorded by the control unit 16.

[0033] Note that, among the components of the processing apparatus 1, for example, the functions of the control unit 16 may be realized by a hardware processor such as a CPU (Central Processing Unit) executing a program (software). Some or all of these components may be realized by hardware (including a circuit unit; circuitry) such as an LSI (Large Scale Integration), an ASIC (Application Specific Integrated Circuit), an FPGA (Field-Programmable Gate Array), or a GPU (Graphics Processing Unit), or may be realized by the cooperation of software and hardware. The program may be stored in advance in a storage device (a storage device having a non-transitory storage medium) such as an HDD (Hard Disk Drive) or a flash memory, or may be stored in a removable storage medium (a non-transitory storage medium) such as a DVD or a CD-ROM, and may be installed by mounting the storage medium on a drive device.

[0034] (Processing performed by the metal material processing apparatus) Next, the processing performed by the processing apparatus 1 according to the present embodiment will be described. FIG. 2 is a flowchart showing an example of the processing performed by the processing apparatus 1 when machining the machining surface 30s of the workpiece 30 using the processing apparatus 1 according to the present embodiment.

[0035] (Step S1) First, the first sensor 21 measures the first relative distance L1 (first measurement step) and outputs the measured first relative distance L1 to the control unit 16. Further, the second sensor 22 measures the second relative distance L2 (second measurement step) and outputs the measured second relative distance L2 to the control unit 16. At this time, the second sensor 22 may measure the third relative distance L3 and output it to the control unit 16.

[0036] (Step S2) Next, the control unit 16 performs height correction of the cutting means 12 with respect to the machined surface 30s based on the measured first relative distance L1 and second relative distance L2. More specifically, when the rotary cutting unit 12b is in the natural position described above, the position of the cutting means 12 is adjusted by controlling the moving mechanism 13 so that the lowest point P of the cutting means 12 (rotary cutting unit 12b) is at the same height as the machined surface 30s.

[0037] By adjusting the position of the cutting means 12 in this way, the cutting means 12 can be brought into contact with the convex portion 31, and the convex portion 31 can be cut by the cutting means 12. Also, it is regulated that the lowest point P of the cutting means 12 is located below the machined surface 30s. Thereby, it is possible to prevent the cutting means 12 from cutting the machined surface 30s more than necessary.

[0038] When eccentricity or deformation has occurred in the cutting means 12, the distance between the cutting means 12 and the second sensor 22 (second relative distance L2) is different at each location of the cutting means 12. In such a case, it is advisable to measure the change in the second relative distance L2 with the second sensor 22 while rotating the cutting means 12 by the rotation mechanism 14. Then, the position of the cutting means 12 may be adjusted based on the point where the cutting means 12 protrudes most toward the workpiece 30, that is, the minimum value of the second relative distance L2. According to this method, even when eccentricity or deformation has occurred in the cutting means 12, the lowest point P of the cutting means 12 can be located below the machined surface 30s, preventing over-cutting of the machined surface 30s.

[0039] As an example, when the value E shown in the following formula (1) is positive, the position of the cutting means 12 may be corrected downward, and when the value E is negative, the position of the cutting means 12 may be corrected upward. Note that the value B is the measured value of the measurement reference distance L3, the value A is the measured value of the first relative distance L1 at the time of measuring the measurement reference distance L3, the value C is the measured value of the first relative distance L1 at the time of correction measurement, and the value D is the minimum value of the measured values of the second relative distance L2 at the time of correction measurement. E = (A - B) - (C - D) …(1)

[0040] (Step S3) Next, the control unit 16 controls the moving mechanism 13 to move the cutting means 12 to a predetermined teaching position (reference position). In FIG. 3, the predetermined reference position is shown as (X, Y) = (0, 0). The teaching position is, for example, a position where the central axis O of the cutting means 12 comes directly above the convex portion 31. Then, the first sensor 21 is translated directly above the machining surface 30s without a convex portion near the teaching position. The first sensor 21 measures the distance to the machining surface 30s, that is, the first relative distance L1. The first sensor 21 outputs the measured first relative distance L1 to the control unit 16.

[0041] (Step S4) Next, the control unit 16 controls the moving mechanism 13 to move the machining point P of the cutting means 12 to a predetermined machining start position. In FIG. 3, the machining start position is shown as (X1, Y1) in the coordinate system of (X, Y). The machining area A shown in FIG. 3 is an area on the machining surface 30s where machining is performed by the cutting means 12. The machining area A is set in advance by the user or the like. The machining area A is, for example, a rectangular area defined by the machining start position (X1, Y1) and the machining end position (X2, Y2). The shape of the machining area A is not limited to the illustrated example and can be changed as appropriate. Usually, the teaching position (X, Y) = (0, 0) is included in the machining area A.

[0042] (Step S5) Next, the control unit 16 controls the moving mechanism 13 to lower the cutting means 12. At this time, the control unit 16 controls the moving mechanism 13 based on the first relative distance L1 and the second relative distance L2 measured in the above steps. Thereby, the position (height) of the cutting means 12 is regulated so that the lowermost point P of the cutting means 12 does not position below the machining surface 30s while the cutting means 12 is brought into contact with the convex portion 31. More specifically, the control unit 16 lowers the cutting means 12 to a position where the lowermost point P of the cutting means 12 positions at the same height as the machining surface 30s if the cutting means 12 is in a natural state.

[0043] As an example, the cutting means 12 may be lowered by a distance F (refer to the upper left of FIG. 1) calculated based on the following formula (2). Note that the value E is the value described in Step S2. F = E …(2)

[0044] The control unit 16 may control the moving mechanism 13 to tilt the scraping means 12 with respect to the processing surface 30s (see FIG. 4A), and may lower the scraping means 12 in this tilted state (see FIG. 4B). That is, the central axis O of the scraping means 12 may be tilted with respect to the vertical direction Z. When tilting the scraping means 12 in this way, the scraping means 12 may be lowered by a distance H calculated based on the following equation (3). The value θ is the tilt angle of the central axis O of the scraping means 12 with respect to the vertical direction Z. In FIG. 4A, the correction value is calculated from the difference between the coordinate P of the machining point P when the machining surface 30s and the line PR are parallel and the coordinate P of the machining point P when tilted by ∠θ from the center point Q. The following conditions are required for the calculation. The point QR is on the straight line of the center line O of the rotation mechanism 14 of the cutting means 12. ·PR and QR are at right angles. ·The plane PQR is parallel to the coordinate plane (X,Z). The following parameters are set as information necessary for the calculation. QR = Line segment QR ·PR=Line segment PR θ = tilt angle (deg) The intermediate calculation formula is as follows: ·Length of line segment QP = QP = √(QR 2 +PR 2 ) ∠PQR=arctan(PR / QR) Reference angle at point P ·∠P3=∠PQR-90(deg) Actual P point angle before tilting ·∠P4=∠PQR-90(deg)+θ Actual angle at point P after tilting (∠P3 and ∠P4 are intermediate calculation variables and are not shown in Figure 4A.) The formula for calculating the descending distance H when tilting is as follows: ·H=F-(sin(∠P4)-sin(∠P3))×QP ···(3) ·The X axis moves in the negative direction by (cos(∠P4)-cos(∠P3))×QP.

[0045] (Step S6) When the cutting means 12 abuts against the convex portion 31, the cutting means 12 becomes floating upward due to the pressing force received from the convex portion 31 (see FIG. 4B). Then, as the convex portion 31 is gradually cut by the cutting means 12, the cutting means 12 descends. The descent of the cutting means 12 stops in the natural state described above (see FIG. 4C). In the above-described step S5, by appropriately adjusting the position of the cutting means 12 using the first relative distance L1 and the second relative distance L2, the lowest point P of the cutting means 12 can be stopped exactly on the processed surface 30s without measuring the height of the convex portion 31 (adjustment processing step).

[0046] In this process, the floating detection unit 15 continuously measures the floating amount of the cutting means 12 at predetermined time intervals and continuously outputs the measured values to the control unit 16. The control unit 16 determines whether or not the floating amount has become zero based on the output value of the floating detection unit 15. When the control unit 16 determines that the floating amount is not zero (step S6; NO), the control unit 16 continues this determination. When the control unit 16 determines that the floating amount has become zero (step S6; YES), the process of step S7 is performed.

[0047] (Step S7) The control unit 16 determines whether or not the X coordinate of the current position of the processing point P of the cutting means 12 has reached the X coordinate (X2) of the processing end position. When the control unit 16 determines that the X coordinate of the current position of the processing point P of the cutting means 12 has not reached the X coordinate (X2) of the processing end position (step S7; NO), the process of step S8 is performed. When the control unit 16 determines that the X coordinate of the current position of the processing point P of the cutting means 12 has reached the X coordinate (X2) of the processing end position (step S7; YES), the process of step S9 is performed.

[0048] (Step S8) The control unit 16 controls the moving mechanism 13 to move the machining point P of the cutting means 12 by a predetermined distance in the first direction X (see FIG. 3). Then, the process of step S6 is performed again. By repeating the processes of steps S6 to S8 in this way, the machining point P of the cutting means 12 moves in the first direction X while cutting the convex portion 31 along the machining surface 30s.

[0049] (Step S9) The control unit 16 determines whether or not the Y coordinate of the current position of the machining point P of the cutting means 12 has reached the Y coordinate (Y2) of the machining end position. When the control unit 16 determines that the Y coordinate of the current position of the machining point P of the cutting means 12 has not reached the Y coordinate (Y2) of the machining end position (step S9; NO), the process of step S10 is performed. When the control unit 16 determines that the Y coordinate of the current position of the machining point P of the cutting means 12 has reached the Y coordinate (Y2) of the machining end position (step S9; YES), the process by the machining apparatus 1 ends.

[0050] (Step S10) (See FIG. 3) The control unit 16 controls the moving mechanism 13 to raise the machining point P of the cutting means 12, reset the X coordinate of the machining point P of the cutting means 12 to the X coordinate (X1) of the machining start position, and move it by a predetermined distance in the second direction Y. This prevents the cutting means 12 and the workpiece 30 from interfering unintentionally while the cutting means 12 is moving. By repeating the processes of steps S5 to S10 in this way, the cutting means 12 can cut the convex portion 31 along the machining surface 30s over the entire machining area A.

[0051] In step S1 of the flowchart shown in FIG. 2, the measurement of the second relative distance L2 (second measurement step) is performed only once, but this measurement may be repeated a plurality of times at predetermined time intervals. And each time this measurement is performed, adjustment of the position of the cutting means 12 by the control unit 16 (adjustment processing step) may be performed. In this case, even if the cutting means 12 is deformed due to wear or the like when the convex portion 31 is cut, the position of the processing point P of the cutting means 12 can be readjusted according to the deformation, and the processing accuracy can be maintained. Further, the control unit 16 may be configured to determine that the cutting means 12 has failed and stop the operation of the processing apparatus 1 when the difference between the maximum value L4 and the minimum value L2 of the second sensor 22 when the cutting means 12 is rotated is equal to or greater than a predetermined value. In this case, the safety of the processing apparatus 1 can be enhanced.

[0052] Further, a program for realizing all or part of the functions of the processing apparatus 1 in the present embodiment may be recorded on a computer-readable recording medium, and the program recorded on this recording medium may be read into a computer system and executed to perform all or part of the processing performed by the processing apparatus 1. Here, the “computer system” is assumed to include hardware such as an OS and peripheral devices. Further, the “computer system” also includes a WWW system having a homepage providing environment (or a display environment). Further, the “computer-readable recording medium” refers to a portable medium such as a flexible disk, a magneto-optical disk, a ROM, a CD-ROM, or a storage device such as a hard disk built in a computer system. Furthermore, the “computer-readable recording medium” also includes a volatile memory (RAM) inside a computer system that becomes a server or a client when a program is transmitted via a network such as the Internet or a communication line such as a telephone line, and that holds the program for a certain period of time.

[0053] Also, the above program may be transmitted from a computer system storing the program in a storage device or the like to another computer system via a transmission medium or by a transmission wave in the transmission medium. Here, the "transmission medium" for transmitting the program refers to a medium having a function of transmitting information, such as a network (communication network) like the Internet or a communication line (communication wire) like a telephone line. Further, the above program may be for realizing a part of the aforementioned functions. Furthermore, it may be a so-called difference file (difference program) that can realize the aforementioned functions in combination with a program already recorded in a computer system.

[0054] As described above, the processing apparatus 1 (metal material processing apparatus) according to the present embodiment includes a processing unit 10 having a cutting means 12 for cutting a workpiece 30 (metal material), a moving mechanism 13 for moving the processing unit 10, a first sensor 21 fixed to the processing unit 10 for measuring a first relative distance L1 to a processing surface 30s on the workpiece 30, a second sensor 22 for measuring a second relative distance L2 to the cutting means 12, and a control unit 16 for controlling the moving mechanism 13 based on the first relative distance L1 and the second relative distance L2 to adjust the position of the cutting means 12 so that the lowest point P of the cutting means 12 does not position below the processing surface 30s while the cutting means 12 is brought into contact with a convex portion 31 on the processing surface 30s. Also, the metal material processing method according to the present embodiment includes a first measurement step in which the first sensor 21 measures the first relative distance L1, a second measurement step in which the second sensor 22 measures the second relative distance L2, and an adjustment processing step of adjusting the position of the cutting means 12 based on the first relative distance L1 and the second relative distance L2 so that the lowest point P of the cutting means 12 does not position below the processing surface 30s while the cutting means 12 is brought into contact with the convex portion 31 on the processing surface 30s.

[0055] With this configuration, it is possible to prevent over-cutting of the processing surface 30s by the cutting means 12. Thereby, the processing of the processing surface 30s can be performed with high accuracy. Also, the processing of the processing surface 30s can be automated by the processing of the control unit 16.

[0056] Further, the cutting means 12 floats by the pressing force received from the workpiece 30. With this configuration, it is possible to reliably prevent the cutting means 12 from being damaged due to overload.

[0057] Further, the processing unit 10 has a rotation mechanism 14 that rotates the cutting means 12. The second sensor 22 measures the change in the second relative distance L2 when the cutting means 12 is rotated, and the control unit 16 adjusts the position of the cutting means 12 based on the minimum value of the second relative distance L2. According to this configuration, even when the cutting means 12 is eccentric or deformed, the processing of the processed surface 30s can be accurately performed.

[0058] Further, the second sensor 22 may measure the second relative distance L2 a plurality of times at predetermined time intervals, and the control unit 16 may adjust the position of the cutting means 12 based on the second relative distance L2 each time the second relative distance L2 is measured. According to this configuration, even if the cutting means 12 is deformed due to wear or the like, the position of the cutting means 12 can be readjusted according to the deformation, and the accuracy of the processing can be maintained.

[0059] Note that the technical scope of the present invention is not limited to the above-described embodiment, and various modifications can be made without departing from the spirit of the present invention.

[0060] For example, the processing apparatus 1 and the processing method described in the above embodiment may be applied to any of a grinding process for largely cutting off the convex portion 31, a finishing process for flattening the processed surface 30s, and other processing processes.

[0061] Further, the processing apparatus 1 may be configured such that the cutting means 12 is replaceable. According to this configuration, the processed surface 30s can be processed using the optimal cutting means 12 in each processing step. Also, by appropriately replacing the cutting means 12, it is possible to perform a plurality of (for example, all) processing steps with one processing apparatus 1. Even if the cutting means 12 is replaced, the processed surface 30s can be accurately processed by adjusting the position of the cutting means 12 based on the first relative distance L1 and the second relative distance L2 as in the above embodiment.

[0062] Also, for each processing step, it may be switched whether to tilt the cutting means 12 with respect to the processing surface 30s. For example, in the grinding step, the cutting means 12 may be pressed against the processing surface 30s perpendicularly, and in the finishing step, the cutting means 12 may be tilted (non-perpendicularly) and pressed against the processing surface 30s. The inclination angle of the cutting means 12 may be made different for each processing step.

[0063] Also, the processing surface 30s may be a flat surface, or if the measurement point of the first relative distance L1 and the processing range (X1, Y1)-(X2, Y2) are on the same straight line, the surface in the vertical direction of that straight line may be a curved surface.

[0064] In addition, within the scope not departing from the gist of the present invention, it is possible to appropriately replace the components in the above-described embodiments with well-known components, and the above-described embodiments and modification examples may also be combined as appropriate.

Explanation of Reference Numerals

[0065] 1... processing apparatus 10... processing unit 11... main body unit 12... cutting means 13... moving mechanism 14... rotating mechanism 15... floating detection unit 16... control unit 21... first sensor 22... second sensor 30... workpiece (metal material) 31... convex portion L1... first relative distance L2... second relative distance

Claims

1. a processing unit having a cutting means for cutting a metal material; a moving mechanism for moving the processing unit; a first sensor fixed to the processing unit for measuring a first relative distance to a processing surface on the metal material; a second sensor fixed to a measuring jig having a reference surface arranged on the same plane as the processing surface, for measuring a second relative distance to the cutting means and a measurement reference distance to the reference surface; a control unit that controls the moving mechanism to adjust the position of the cutting means such that when the measured value of the measurement reference distance is B, the measured value of the first relative distance at the time of measuring the measurement reference distance is A, the measured value of the second relative distance is D, and the measured value of the first relative distance at the time of measuring the second relative distance is C, the value of E = (A - B) - (C - D) becomes 0, and based on the first relative distance and the second relative distance, the position of the cutting means is adjusted so that the lowest point of the cutting means does not lie below the processing surface while bringing the cutting means into contact with a convex portion on the processing surface; a metal material processing apparatus.

2. The cutting means floats by a pressing force received from the metal material. The metal material processing apparatus according to Claim 1.

3. The processing unit has a rotating mechanism for rotating the cutting means. The second sensor measures a change in the second relative distance when the cutting means is rotated. The control unit adjusts the position of the cutting means based on the minimum value of the second relative distance. The metal material processing apparatus according to Claim 1 or 2.

4. The second sensor measures the second relative distance a plurality of times at predetermined time intervals. The control unit adjusts the position of the cutting means based on the second relative distance each time the second relative distance is measured. The metal material processing apparatus according to Claim 1 or 2.

5. a processing unit having a cutting means for polishing a metal material; a moving mechanism for moving the processing unit; a first sensor fixed to the processing unit for measuring a first relative distance to a processing surface on the metal material; a second sensor fixed to a measuring jig having a reference surface arranged on the same plane as the processing surface, for measuring a second relative distance to the cutting means and a measurement reference distance to the reference surface; using a metal material processing apparatus comprising a control unit; a first measurement step in which the second sensor measures the measurement reference distance and the first sensor measures the first relative distance; A second measurement step in which the second sensor measures the second relative distance and the first sensor measures the first relative distance; When the measured value of the measurement reference distance in the first measurement step is B, the measured value of the first relative distance in the first measurement step is A, the measured value of the second relative distance in the second measurement step is D, and the measured value of the first relative distance in the second measurement step is C, the control unit controls the moving mechanism so that the value of E = (A - B) - (C - D) becomes 0, adjusts the position of the cutting means, and while bringing the cutting means into contact with the convex portion on the machining surface, the control unit controls the moving mechanism based on the first relative distance and the second relative distance so that the lowest point of the cutting means is not located below the machining surface. An adjustment machining step for adjusting the position of the cutting means; A metal material processing method.

6. In the second measurement step* the second sensor measures the change in the second relative distance while rotating the cutting means* In the adjustment machining step* the control unit adjusts the position of the cutting means based on the minimum value of the second relative distance. The metal material processing method according to claim 5.

7. The second measurement step and the adjustment machining step are repeated a plurality of times at predetermined time intervals. The metal material processing method according to claim 5 or 6.

8. The cutting means is configured to be replaceable. The metal material processing apparatus according to claim 1 or 2.

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