Systems for automating machine tools

Abstract

The present invention relates to a system for automating a machine tool, comprising an external device (108) for loading and / or unloading workpieces and / or tools to and / or from the machine tool (102), at least one actuator (110) for actuating components of the machine tool (102) and / or at least one sensor (112) for detecting at least one signal of a display component (102a) or a state of the machine tool (102) or the external device (108), and a control unit (106) configured to initiate at least one function of the machine tool (102) or the external device by controlling the at least one actuator (110) and / or to initiate at least one function of the external device (108) depending on a signal of the at least one sensor (112).

Description

[Technical Field]

[0001] The present invention relates to a system for automating machine tools. [Background technology]

[0002] A conventional automation solution generally consists of a machine tool, a robot located outside the machine tool for loading and / or unloading workpieces and / or tools from the machine tool, a parts storage unit, and a workpiece storage unit. Grippers for the tools and clamping means for clamping the workpieces are provided in the normally closed machining space of the machine tool, which can be opened for loading and unloading of workpieces or tools. In other words, this automation solution takes over the loading and unloading of workpieces and / or tools from the machine tool instead of the operator.

[0003] In known systems of this type, machine tools and other components are equipped with electrical interfaces for automating the machine tool, via which they communicate with each other or with a higher-level control unit, which can control the machine tool and other components accordingly. The direct control of the clamping means provided on the machine tool, which is generally operated by hydraulic oil or compressed air, is usually performed by the machine tool itself. To be able to control the clamping means on the rotary table of a five-axis milling machine, for example, a costly rotary introducer for such a clamping means must be routed through the rotary table to route the pressure medium and, if necessary, an electrical control line for operating a directional control valve to the clamping means.

[0004] Typically, these types of communication interfaces are configured by machine tool manufacturers as proprietary interfaces to link their own automation components. Therefore, third-party manufacturers of automation components often have no access to machine tools, either because the manufacturers do not publish the electrical specifications of the interface or because costly mechanical adapters are required to mechanically link the third-party manufacturer's components. Furthermore, in practice, many machine tools are not designed or suitable for integration into automation solutions and therefore do not have any suitable interfaces. The necessary hardware also does not exist, particularly rotary feedthroughs for rotary tables or automatic drives for opening and closing machine doors. Possible retrofitting is often not realized due to the high costs involved. Summary of the Invention

[0005] The object of the present invention is therefore to provide a system for automating machine tools which allows the incorporation of machine tools that do not have suitable interfaces for linking automation solutions, such as external devices for loading workpieces and / or tools into and / or from the machine tool, and which can be implemented in a simple and cost-effective manner.

[0006] The aim is therefore to create an automation that takes over all operator activities for loading and unloading a machine, without the need to retrofit the machine with additional interfaces, automation software, etc. It is a further object of the invention to create a computer program product as well as actuators and sensors for a system of this kind.

[0007] The present invention solves these problems by the features of claims 1 to 13, 14 and 15.

[0008] The present invention is based on the finding that an interface to a machine tool to be automated can be omitted by using an external device (hereinafter also referred to as a "robot") for loading workpieces and / or tools to and from the machine tool, provided that suitable actuators and / or sensors are used, which are connected to a control unit configured to trigger at least one function of the machine tool by controlling at least one actuator and / or to trigger at least one function of an external device depending on the signal of at least one sensor. This allows the system of the present invention, which serves as an automation solution, to take on certain operator roles, such as pressing a start button on the machine tool's operating panel or opening and closing the machine tool door depending on the display on the machine tool's operating panel. The external device can be configured as a stationary robot and can include one or more magazines for storing workpieces and / or tools. The external device is typically positioned (stationary) in front of a door-closable opening in the machining space of the machine tool and has at least one arm for loading and unloading tools or workpieces from the machine tool. Naturally, several workpieces and / or tools can be simultaneously loaded during the loading process and several workpieces and / or tools can be simultaneously removed during the unloading process, for which purpose several workpieces and / or tools can be arranged and held in a magazine.

[0009] The control unit may be integrated into an external device or may be configured as a higher-level control unit that communicates with a machine control unit included in the external device, the machine control unit and the higher-level control unit being configured for wireless communication in order to avoid expensive cabling.

[0010] In a very simple embodiment, the control unit may be integrated into the external device. In particular, the machine control unit and the control unit (responsible for the automation functions) may be integrated, i.e., configured as a single control unit. In this case, as a basic automation, at least one specific function of the external device may be triggered depending on the signals of one or more sensors that detect parameters or states of the machine tool. In such cases, actuators for operating machine tool components, such as electric switches or other adjustment elements of the machine tool, are not necessarily required, since the link between the machine control unit and the control unit is already established.

[0011] In another embodiment, only one or more actuators may be provided, and no separate sensors are provided for detecting at least one signal of the display component or for detecting the state of the machine tool or external device.

[0012] In most cases, however, one or more actuators and one or more sensors are provided, in particular in order to achieve as complete an automation of the machine tool as possible.

[0013] In one embodiment of the invention, at least one actuator and at least one sensor are wirelessly connected to the control unit, which eliminates the need for communication cables between the sensor or actuator and the control unit, which is particularly useful for sensors or actuators that are located on moving parts of the machine tool, such as a rotary table.

[0014] In one embodiment of the invention, the at least one actuator may be configured as an operating element / actuating device and may have at least one electrically, pneumatically or hydraulically driven operating element, which may be configured as a linearly movable operating element suitable for actuating, for example, a push switch or a push key on an operating panel of a machine tool.

[0015] Alternatively, the actuator may be configured as a door opener for a single or double door of the machine tool, for which purpose the actuator may also have an actuating device, for example in the form of a drive roller, for opening and closing the door, which may be configured as a double door.

[0016] The actuator according to the invention can also be configured as a clamping device for use in a machine tool, which can serve to clamp a workpiece directly or to fasten another clamping device, such as a vice, which can also be configured as an actuator according to the invention.

[0017] In one embodiment of the invention, at least one sensor can be configured as an optical sensor, for example as a photodiode or a camera. Such a sensor can be arranged, for example, on a control panel of a machine tool and can detect the state of a light-emitting diode or the output on a screen (in the form of any display or text). The sensor can be configured to transmit only a direct sensor signal with the relevant information content to the control unit, or the signal processing can already be performed in the sensor and only the result of the signal processing, for example the on / off information for the light-emitting diode, can be transmitted to the control unit.

[0018] In one embodiment of the present invention, at least one sensor and / or at least one actuator can be configured to be connectable, for example, glued or screwed, to a machine tool, in particular to an operating panel or housing of the machine tool. This allows for easy assembly of such sensors or actuators. In particular, one or more suitable mounting surfaces of the sensor or actuator can already be provided with a suitable adhesive covered with a removable film. To assemble, it is sufficient to peel off the film and place the sensor with its mounting surface on the corresponding surface of the machine tool and press it.

[0019] The sensor according to the invention can be designed to monitor the clamping force or the correct clamping state of a clamping device, in particular a clamping device according to the invention, in the latter case the sensor and the actuator can be designed as an integrated module.

[0020] It should be pointed out here that of course any embodiment of a sensor or actuator may be configured as an independent module.

[0021] In one embodiment of the system according to the invention, selected or all sensors and actuators can be configured autonomously and each can include its own, particularly rechargeable, energy supply. This energy supply can be, in particular, an electrical energy supply, for example, in the form of a rechargeable battery. The battery can then be charged inductively, i.e., contactlessly, or via cable by connection to a charging device. Of course, it is also possible to replace the battery and recharge it externally each time, or to use a non-rechargeable battery. Subsequently or additionally, the energy supply can also be provided in the form of a pneumatic pressure reservoir. In this case, recharging can be achieved, for example, by supplying compressed air via a movable arm of an external device. The autonomous embodiment of the sensors or actuators makes it possible to ensure their respective functionality without the need to establish a continuously continuous energy supply via the machine tool or an external device.

[0022] As already explained above, in the present invention the external device can be configured as a stationary device with at least one movable arm for loading and / or unloading workpieces and / or tools into and / or from the machine tool, the at least one arm additionally serving to supply compressed air to actuators configured for pneumatically actuating the respective actuating members.

[0023] The control unit can, according to the invention, contain a computer program which, when executed in the control unit of the machine tool, is configured to communicate with an external device and to control at least one actuator, possibly taking into account information supplied by at least one sensor, so that the execution of processes in the machine tool is automated, in particular the initiation of a machining procedure on a workpiece, the opening and closing of the machine tool door, the removal of a workpiece that has been partially or completely machined or the introduction of a new workpiece to be machined, the introduction and removal of tools into the machine tool, etc. The computer program can naturally be stored in the control unit or can be stored on a data carrier, in the cloud, etc. and can be loaded into the working memory of the control unit from the data carrier or the cloud.

[0024] Further embodiments of the invention are apparent from the dependent claims.

[0025] The invention will now be described in more detail with reference to the embodiments illustrated in the drawings, in which: [Brief explanation of the drawings]

[0026] [Figure 1] 1 illustrates an embodiment of a system for automating a machine tool in relation to a machine tool, substantially in perspective view; [Figure 2] FIG. 2 is a plan view of the drawing of FIG. 1. [Figure 3] FIG. 2 is a plan view of the embodiment shown in FIG. 1, but omitting the machine tool to be automated. [Figure 4] 1 is a perspective view of an autonomous actuator according to the present invention; FIG. [Figure 5] FIG. 5 is a view similar to FIG. 4, but showing the actuator lifted from the mounting shoe. DETAILED DESCRIPTION OF THE INVENTION

[0027] Figure 1 shows, substantially in perspective view, an overall system 100 consisting of a machine tool 102 and a system 104 for automating the machine tool. Only a control unit 106 included in the automation system 104, as well as the respective communication connections, are shown schematically in the form of a block diagram. Figure 2 shows a plan view of the overall system 100 of Figure 1.

[0028] FIG. 3 shows the automation system 104 again in the same view without the machine tool 102 for better overview.

[0029] As can be seen from these figures, the automation system 104 includes a control unit 106 and an external device 108 for loading and / or unloading workpieces and / or tools into and / or from the machine tool, which will also be referred to as a "robot" for brevity within the scope of this description. Furthermore, the automation system 104 includes a number of actuators 110 in the form of a clamping device 110a configured as a vice, a clamping device 110b configured as a zero-point clamping system (FIG. 2), a door opener device 110c, and an operating element / actuator 110d. Finally, the automation system 104 includes at least one sensor 112. In this example, the sensor 112 is integrated into the operating element / actuator 110d (FIG. 4). At least one sensor (not shown) is also integrated into each of the actuators 110a, 110b, and 110c. In the case of the vice 110a and the zero-point clamping system 110b, this is a pressure sensor if these are configured as pneumatically or hydraulically acting components. The door opener device 110c can also include sensors for detecting the position of the door or the drive (and thus the door). Therefore, in Figures 1 to 3, the communication connections between these actuators 110 and the control unit 106 are shown as bidirectional connections.

[0030] These components allow the automation system 104 to automate the machine tool 102 to a certain extent and thereby to automate and configure actions that would otherwise have to be performed by an operator in a non-automated machine tool, such as loading and / or unloading workpieces and / or tools into and / or from the machine tool 102, opening and closing the machine tool door 114 enclosing the machining space, and starting a machining cycle.

[0031] The robot 108 has at least one assignable arm 108a, which enables the robot 108 to grasp a workpiece or tool (not shown) and transfer it to or from the processing space of the machine tool 102. The robot may also have a magazine (not shown) for storing or stockpiling workpieces and tools.

[0032] In the embodiment shown in the drawings, the machining space of the machine tool 102 is provided with a zero-point clamping system 110b, which may be mounted, for example, on a rotary table of the machine tool. In the illustrated example, an actuator 110 in the form of a controllable vice 110a is held on the zero-point clamping system 110b. The zero-point clamping system 110b is also configured as a controllable actuator 110. Both actuators 110a and 110b are controllable at least in such a way that the respective actuator can be moved into a clamped position or a released position by a control command.

[0033] Of course, each actuator, i.e., each of actuators 110a and 110b, can also be provided with a sensor that detects a particular result or state, for example whether the respective actuator has moved from one position to another and / or whether a predetermined position has actually been reached or maintained, etc. However, one or more such sensors may also be configured as their own module.

[0034] The actuator 110 configured as a door opener device 110c has a drive configured to move a door, which may be configured as a sliding door, from an open position to a closed position. The door opener device 110c, like all other actuators, can be configured as an independent module. Such a module can be subsequently coupled to the housing or floor of the machine tool 102 at a location where the drive is linked to the movable door 114. Naturally, the door opener device 110c can also be equipped with one or more sensors for detecting the respective position of the drive and / or the door 114.

[0035] The actuator 110 configured as an operating member / actuating device 110d is arranged on the operating panel 102a of the machine tool 102 and is configured to actuate one or more assigned operating members of the operating panel 102a.

[0036] As is clear from FIG. 4, the actuator 110d may also be configured as an independent module. The housing 116 of the operating member / actuating device 110d is provided with an electric, programmable, or hydraulic drive for the actuating member 118. In the illustrated embodiment, the actuating member 118 is configured as a linearly movable cylindrical member that protrudes downward from the housing 116. The housing 116 has four legs 120 on its underside, which allow the operating member / actuating device 110d to be mounted on and connected to the operation panel 102a. This connection can be achieved, for example, by gluing or screwing. In either case, the connection must be configured so that the housing is fixed against sliding or lifting relative to the surface of the operation panel 102a when the actuating member 118 applies a force to actuate the corresponding operating member (not shown) of the operation panel 102a. For assembly, the control member / actuator 110d must be aligned over the appropriate control member of the control panel 102a so that the actuating member 118 is positioned correctly over the control member to be actuated, and when in this position, the housing 116 is mated with the control panel 102a.

[0037] In the embodiment of the actuator 110d shown in FIG. 4, attachment to a base, such as the surface of the operating panel 102a of the machine tool 102, is achieved by a permanent magnet 124 attached to the underside of the leg 120, e.g., held in a corresponding recess in the underside of the leg 120 (see FIG. 5). To enable easy removal and dismantling of the actuator 110d, a mounting shoe 126 is provided, which can be fixedly connected to the base at its underside, e.g., by gluing or screwing. The mounting shoe 126 has recesses in its upper region, into which the lower region of the leg 120 can be inserted. These recesses are designed to secure the leg against lateral sliding. The mounting shoe can be made of a ferromagnetic material to ensure the highest possible attachment force between the magnet 124 and the fixedly connected leg 120. However, the bottom surface of the cup-shaped mounting shoe 126 may be configured to provide sufficient mounting force in another embodiment where the material of the mounting shoe 126 is not selected to be ferromagnetic, but is made of, for example, plastic.

[0038] FIG. 5 shows the actuator 110d in a position where the actuator leg 124 is disengaged or lifted from the mounting shoe 126. The embodiment of the actuator 110d shown in FIGS. 4 and 5 thus allows for easy mounting of the actuator to a base, for example by gluing the base to the mounting shoe 126, and for removal of the actuator by simply lifting the actuator 110d from the mounting shoe 126, with the mounting shoe remaining connected to the base. Nevertheless, the actuator 110d is sufficiently securely connected to the base by the mounting shoe 126, and is secured against lateral sliding. Lifting the actuator 110d allows for easy manual actuation of the actuating members normally actuated by the actuator 110d, if necessary. This naturally also applies to other actuating members that are hidden by the actuator 110d in the assembled position.

[0039] 4 includes a WLAN module 122, along with an antenna, not shown in detail, located within the housing 116. This type of wireless connection may, of course, be contemplated for any otherwise configured actuator 110 or for any sensor 112.

[0040] As already mentioned above, a sensor is also arranged in the housing of the actuator 110d, which is configured to detect whether the corresponding operating member has a certain status. For example, the operating member can be configured as an illuminated push button, the illumination of which is activated when the push button can / must be pressed, for example, to initiate a machining cycle of the machine tool 102. In this case, the sensor is configured as an optical sensor. Naturally, sensors can also be configured to detect the status of other display members of the operating panel 102a and, possibly, depending on this, to initiate an action, for example, by pressing an associated key or activating an associated switch.

[0041] The sensor may, of course, be configured in any other way. The optical sensor may also be configured as a camera, detecting any other indication on the display or operating panel (e.g., an error indication by an LED or other light-emitting means) or detecting the state of any other component of the machine tool. Image evaluation methods (including OCR methods) enable the control unit 106 to determine the required sensor information from the sensor signals supplied to it (in this case, the image signals of the camera), for example, to determine on behalf of the operator the requirements for a particular tool as plain text or symbols on the screen, and depending on this, to control the robot 108 and / or the actuator 110 in an appropriate manner. Similarly, it is also conceivable that, via the sensor 112 configured as a camera, any information on the screen or operating panel 102a of the machine tool 102 is recognized and transmitted, in particular streamed, to one or more other network subscribers in the same network as the automated machine tool 102 or the entire system 100.

[0042] The sensor 112 may be configured to transmit only a pure sensor signal to the control unit 106, which then evaluates the sensor signal and examines it, for example, for certain characteristic results. Alternatively, the sensor 112 may have some intelligence and, in particular, be configured to perform advanced processing of the directly detected sensor signal. In this case, the sensor can already transmit certain information, for example, as digital information, to the control unit. For example, the optical sensor 112 may be configured to recognize the color of a display LED and transmit the corresponding information, for example, "red," "green," or "yellow," to the control unit 106.

[0043] The robot 108, as well as the actuators 110 and sensors 112, may be communicatively connected to the control unit 106 in any manner. While a cabled connection is contemplated for the connection with the robot 108, a wireless connection is preferably used for the connection between the sensors 112 and actuators 110 and the control unit 106. This allows for significantly greater flexibility and reduces the costs associated with cabling. Furthermore, actuators positioned within the machining space of the machine tool 102 are also associated with the difficulties of routing the corresponding cabling to the outside. Furthermore, if the actuators are arranged on a movable member, such as a rotary table of the machine tool 102, cost-intensive rotary feedthroughs are not required. However, of course, if this is always necessary or desirable for some reason, the sensors 112 and actuators 110 can also be connected to the control unit 106 via a cabled connection.

[0044] The control unit 106 may be located inside or on the robot 108 or may be integrated into the control unit of the robot 108. Of course, the control unit 106 may also be located anywhere else, for example in a control station for an automated machine tool or in a control station for multiple automated machine tools.

[0045] The actuators 110 and the sensors 112 can in particular be configured as autonomous modules, and a module of this kind can also include several actuators 110 and / or sensors 112. For this purpose, the relevant module can be equipped with its own energy supply, for example a rechargeable battery. Instead of a rechargeable battery, of course, a replaceable battery can also be provided.

[0046] As an alternative or in addition to an electrical energy supply, a pressure energy supply, in particular a pneumatic energy supply, can also be provided. For example, a pneumatically acting actuator 110 can be equipped with a pressure reservoir, which can also be refillable. For this purpose, for example, the actuator can be equipped with a pressure connection, and compressed air can be supplied to it, for example by the arm 108a of the robot 108, for example by means of a compressed air lance that is inserted into the compressed air connection. This type of embodiment is particularly suitable for an actuator 110 configured as a pneumatic clamping device, for example in the form of a vice 110a or a zero-point clamping system 110b.

[0047] Finally, it should be pointed out that the actuator 110, in particular the actuator configured as the operating member / actuator 110d, can be arranged at any point in the machine tool to be automated or in a component connected thereto where a required action must be initiated. For example, if an existing door opener device is provided with an operating member, such as an electric switch, for initiating the desired door movement, the operating member / actuator 110d can also be positioned in this door opener device.

[0048] The same applies to sensors 112. These sensors can also be arranged at any point on the machine tool to be automated or on a component connected thereto where parameters or information required for the automation of the machine tool must be detected.

[0049] The control unit 106 can be embodied in the usual way as a combination of hardware and software, the software being configured in particular to evaluate sensor signals or information provided by the sensors and to trigger the functions of the actuators depending on preset parameters that can also be determined from the sensor signals. The software can be permanently stored in the control unit 106, even in the form of full or partial firmware, or can be made accessible to the control unit 106 by means of an external memory (including a cloud memory) for running within the control unit. Finally, it is also possible for the software to run in a higher-level control unit and only supply it with signals and / or information provided by the sensors, and for control signals provided by the higher-level control unit to a local control unit connected to the sensors and actuators, for example provided on the robot 108. [Explanation of symbols]

[0050] 100 Overall system consisting of automation system and machine tools 102 Machine tools 102a Operation panel 104 Automation Systems 106 Control Unit 108 External Devices / Robots 108a Arm 110 Actuator 110a vise 110b Zero Point Clamp System 110c Door Opener Device 110d Operating members and actuators 112 Sensors 114 Door 116 Housing 118 Actuating member 120 Legs 122 WLAN Module 124 Magnet 126 Mounting shoe

Claims

1. 1. A system that is added to a machine tool to automate the machine tool, comprising: (a) an external device (108) for loading and / or unloading workpieces and / or tools onto and / or from the machine tool (102); (b) at least one actuator (110) for actuating a component of the machine tool (102) and / or at least one sensor (112) for detecting at least one signal of a display component (102a) of the machine tool (102) or a state of the machine tool (102) or the external device (108); (c) a control unit (106) configured to initiate at least one function of the machine tool (102) or the external device (108) by controlling at least one of the actuators (110) and / or to initiate at least one function of the external device (108) depending on a signal of at least one of the sensors (112). and (d) the machine tool (102) does not have a communication interface connected to the system; A system for automating machine tools.

2. The system according to claim 1, characterized in that at least one of the actuators (110) and / or at least one of the sensors (112) are wirelessly connected to the control unit (106).

3. 2. The system of claim 1, wherein the actuator (110) is configured as an operating member / operating device (110d) and has at least one operating member (118) that is electrically, pneumatically, or hydraulically driven.

4. 2. The system according to claim 1, wherein the actuator (110) is configured as a door opener device (110c) for a single or double door (114) of the machine tool (102).

5. The system of claim 1, wherein the actuator (110) is configured as a clamping device (110a, 110b) for use with the machine tool (102).

6. The system of claim 1 , wherein at least one of the sensors (112) is configured as an optical sensor.

7. The system of claim 1, wherein at least one of the sensors (112) and / or at least one of the actuators (110) is configured to be coupleable with the machine tool (102).

8. 6. The system according to claim 5, characterized in that at least one of the sensors is configured for monitoring the clamping force or correct clamping state of the clamping device (100a, 100b).

9. The system of claim 1, wherein selected or all of the sensors (112) and actuators (110) are configured autonomously and include their own energy supply.

10. 2. The system according to claim 1, characterized in that the external device (108) is configured as a stationary device having at least one movable arm (108a) for loading and / or unloading workpieces and / or tools to and / or from the machine tool (102).

11. 2. The system according to claim 1, wherein the control unit (106) includes a computer program configured, when proceeding in the control unit (106), to communicate with the external device (108) and to control at least one of the actuators (110) so that the progression of the process of the machine tool (102) is automated with respect to starting a machining procedure on a workpiece, opening and closing a door (114) of the machine tool (102), removing a workpiece that has been partially or fully machined or introducing a new workpiece to be machined, and introducing and removing tools to and from the machine tool (102).

12. 2. The system according to claim 1, wherein the control unit (106) is configured as an independent host control unit separate from the external device (108) and the machine tool (102), and connected to the external device (108) and at least one of the actuators (110) and / or at least one of the sensors (112).

13. 13. A computer program for a system (100) according to any one of claims 1 to 12, said computer program comprising commands for initiating at least one function of said machine tool (102) by controlling at least one actuator (110) and / or for initiating at least one function of said external device (108) depending on a signal of at least one sensor (112).

14. 13. An actuator for a system according to any one of claims 1 to 12, characterized in that at least one of the actuators (110) is configured autonomously and therefore has its own energy supply and is configured for wireless communication with the control unit (106) of the system (100).

15. 13. A sensor for a system according to any one of claims 1 to 12, characterized in that the sensor (112) is configured autonomously and therefore has its own energy supply and is configured for wireless communication with the control unit (106) of the system (100).

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