Collision inspection method for machining process using substitute workpiece

Abstract

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

Description

[Technical Field]

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

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

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

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

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

[0006] Collision inspection is often performed visually using machine tool tools. The original machined component is assembled on the machine tool and, under the supervision and control of an operator, is carefully, often step-by-step, brought as close as possible to the desired position of the machined component. The operator then repeatedly observes the machined component to determine whether an unintended collision will occur and, if necessary, halts the approach to the desired position.

[0007] This approach is often difficult. During collision testing, the operator often cannot adequately view the machined component, even when the machine tool is turned off and the machine housing is repeatedly opened. The workpiece often obscures other machined components, especially when the workpiece's radially inner side must be machined. While optical aids, such as mirrors or endoscopes, can sometimes improve the operator's visibility, there is often insufficient space for such aids. Another drawback is that during collision testing, the workpiece and tool begin to interlock, often preventing the operator from approaching the machined component at all. In this case, the operator must mentally add the remaining depth of cut or the remaining feed to the set position and then mentally estimate the collision situation. If the operator does not recognize an impending collision when gradually approaching the desired position, the original machined component may be damaged during collision testing, and tool replacement, especially if damage occurs, is often very expensive.

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

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

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

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

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

[0013] By using the substitute machined components, it is possible to protect parts that may collide with the corresponding original or substitute machined components during a collision test from damage. The substitute machined components are basically manufactured from a cost-effective, flexible material (preferably an elastic or easily plastically deformable material). In the event of a collision during a collision test, only the substitute machined component or components are deformed, which is not damaging, or at least not significantly damaging, and no damage occurs to other parts, such as the machine tool or a model of the machine tool. Typical materials for the substitute machined components are plastic, metal plate (preferably with a plate thickness of about 2 mm, or a plate thickness of 1 mm to 3 mm), or cardboard / cardboard.

[0014] On the other hand, the present invention contemplates forming the replacement workpiece not as a complete copy of the original workpiece, but as a partial copy of the original workpiece. The workpiece is replicated by the replacement workpiece over only a portion of its circumference, at least in an axial subregion of the workpiece. In other words, in the replication, a portion of the workpiece's circumference is omitted at least in an axial subregion, and in the replication (at least in an axial subregion) at least one-third of the workpiece's circumference is omitted in the replacement workpiece.

[0015] This can essentially allow the operator better visibility of the machined component and the alternate machined component, making it easier to recognize potential collisions. Particularly in the case of internally toothed workpieces, the alternate workpiece allows for a radially inward view of the workpiece that would not be possible with the original workpiece. However, by rotating the alternate workpiece (typically by hand), it remains possible to inspect the entire circumference of the workpiece (and especially those portions of the workpiece's circumference that are not replicated with the alternate workpiece) for collisions with the alternate workpiece.

[0016] Typically, the teeth of the workpiece are also replicated over only a portion of the circumference. In this case, in a collision check, the tool or substitute tool can simulate its full depth of cut and full feed by bringing the substitute workpiece into a rotated position where it engages the non-replicated portion of the circumference of the substitute workpiece. By rotating the substitute workpiece up to the tool or substitute tool, it is still possible to easily estimate whether a collision will occur. It should be noted that alternatively or additionally, the teeth of the workpiece can be replicated, at least locally, in the substitute workpiece by an envelope or envelope surface corresponding to the root circle of the teeth, which likewise allows the simulation of full depth of cut and full feed. In general, the tool and the workpiece are rotationally symmetric (the number of symmetries corresponds to the number of teeth in the teeth).

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

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

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

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

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

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

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

[0024] Preferred variants of the invention In an advantageous variant of the method according to the invention, the reconstruction of the relative positions of the machining components is carried out on a model of the machine tool that is separate from the machine tool, so that a collision check (e.g. of the machining process to be set up next) can be carried out without interrupting production (of the previous machining process) on the machine tool. The machine axes of the typically non-motorised machine tool are replicated in the model.

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

[0026] A preferred development of this variant is that the machine tool has at least one workpiece spindle with at least one clamping means, and the substitute workpiece is attached to the clamping means for reproduction. By using the original clamping means on the workpiece spindle of the machine tool, the attachment of the substitute workpiece for collision testing is particularly simple. If the machine tool has multiple workpiece spindles, the substitute workpiece can be attached to one or more workpiece spindles, each using its own clamping means.

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

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

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

[0030] In a preferred embodiment, the replacement workpiece has an axial partial region in which the workpiece is replicated over only a portion of the workpiece's circumference and a remaining axial region in which the workpiece is replicated over its entire circumference. In particular, the portion of the circumference is intended to have a plurality of partial structures spaced apart in the axial partial region. The remaining region allows the replacement workpiece to be attached, for example, to a clamping means like a workpiece. Having the replacement workpiece open over a portion of the circumference in the axial partial region improves the operator's visibility, especially in the case of internally toothed workpieces. Separate partial structures, for example, two partial structures spaced about 180° apart or three partial structures spaced about 120° apart, allow particularly good visibility. In some cases, the partial structures can also be involved in clamping the replacement workpiece (e.g., with a jaw chuck or scroll chuck). The partial structures usually extend over only a small angular range in the circumferential direction, usually less than 30°, in particular less than 20°.

[0031] Furthermore, a variant is preferred in which the replacement workpiece replicates the workpiece at least in an axial partial region over at least one-third of its circumference and up to two-thirds of its circumference, in particular the partial workpiece is formed as a half workpiece. The use of such partial workpieces allows the collision situation to be particularly clearly indicated to the operator, which the operator can understand particularly easily and quickly. Usually, only a slight rotation of the replacement workpiece is required for the collision inspection. In partial workpieces, the replicated portions of the workpiece circumference are typically connected in the circumferential direction.

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

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

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

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

[0036] Furthermore, a further advantageous development of the above variant is that the substitute workpiece fully or partially replicates the cross-sectional contour of the workpiece and / or clamping means using a light beam, in particular a laser beam. The light beam eliminates the risk of damage that may occur during collision testing. Furthermore, the light beam often allows the operator to recognize collisions particularly easily. A set of light sources (e.g., laser diodes in the magnet holder) typically allows for problem-free replication of multiple cross-sectional contours of different workpieces, and possibly even clamping means, thereby enabling widespread use of this procedure. The light beam preferably has a wavelength or wavelength spectrum in the visible spectral range, and the light beam is selected with an intensity that is harmless to the human eye. Typically, at least three light beams are used simultaneously (e.g., at least two light beams horizontally and at least one light beam vertically). Alternatively, rods, cords, or wires can be used instead of light beams to partially replicate the cross-sectional contours. Alternatively, the substitute workpiece can be produced by holography.

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

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

[0039] A preferred development of this variant provides that the substitute tool is a partial copy of the tool, in which the tool is replicated over only a portion of the tool's circumference, at least over a partial axial region, and that the substitute tool is rotated around its tool axis in the replicated relative position. This also improves the operator's visibility of the collision situation. By rotating the substitute tool, parts of the tool's circumference that were not replicated on the substitute tool can also be checked for collisions. The partial copy of the tool, like the partial copy of the workpiece, can be realized in particular using a two-dimensional template.

[0040] Also preferred is a development in which the one or more replacement machining components comprise a replacement tool holder that is a copy or partial copy of a tool holder for holding a tool in a tool spindle of the machine tool, whereby the tool holder is also fully protected from damage during the collision test and, in some cases, the operator's visibility of the tool holder can also be improved.

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

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

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

[0044] Furthermore, a variant in which the machining component includes at least one auxiliary tool is advantageous, in particular, the at least one auxiliary tool includes a gas nozzle assembly and / or a suction nozzle assembly and / or a cooling / lubricant nozzle assembly and / or a centering sensor. One or more auxiliary tools can also be referred to as supplementary tooling. The at least one auxiliary tool is used to assist the tool in directly machining the workpiece before or during machining, and the auxiliary tool itself is typically not used to directly machine the workpiece. When reconstructing the relative positions of the machining components, the original auxiliary tool of the machine tool is typically used, but alternative auxiliary tools can also be used. By taking auxiliary tools into account in the collision inspection, unintended collisions involving the auxiliary tool can also be detected, thereby potentially preventing damage.

[0045] A preferred development of this variant provides for optimizing the function of at least one auxiliary tool, particularly by positioning, aligning, and / or selecting the auxiliary tool, in the replicated relative position relative to at least one inspection position. By only partially duplicating the workpiece with an alternative workpiece and, where appropriate, the machining component with an alternative machining component, the auxiliary tool is easily visible and accessible, which makes it particularly easy to optimize the auxiliary tool, particularly its positioning and alignment, within the scope of the collision inspection. For example, the blow nozzle can be particularly precisely aimed at areas where chips are generated or where chips may accumulate.

[0046] A particularly preferred variant is one in which the workpiece partially replicated by the substitute workpiece is an internally toothed workpiece. Internally toothed workpieces are particularly difficult to visually inspect for collisions in conventional applications, since the workpiece virtually completely obscures the teeth to be machined and other structures located inside. When a partial replica of a workpiece is used as a substitute workpiece according to the present invention, the substitute workpiece is open over at least a portion of the workpiece's circumference, which significantly improves visibility of the workpiece. Therefore, the present invention is particularly useful for internally toothed workpieces. Alternatively, the present invention can also be used, for example, for externally toothed or spur-toothed workpieces. Generally, the workpieces inspected for collisions within the scope of the present invention can have one or more teeth.

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

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

[0049] Furthermore, it is advantageous to provide at least one boundary marking on at least one alternative machining component, which indicates the boundaries of the structure of the associated machining component that is not replicated or not fully replicated on the alternative machining component. The boundary marking can, for example, indicate the beginning and end of a toothing that is not replicated or not fully replicated at least locally on the alternative machining component. The boundary marking can make it easier for the operator to recognize collisions in areas of the not-replicated or not-fully replicated structure. The not-replicated or not-fully replicated structure can allow for adjustment of the fully infeed and / or fully fed relative positions of the alternative machining component and the machining component, which would not be possible with a fully replicated structure.

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

[0051] The scope of the present invention also includes a machine tool system designed to perform the above-described method according to the present invention, which includes a machine tool for machining at least one workpiece and one or more substitute machining components, each of which is a copy or partial copy of a corresponding machining component of the machine tool, including a substitute workpiece that is a partial copy of the workpiece, where the workpiece is replicated over at least an axial subregion and only over a portion of the workpiece's circumference. Using the machine tool system according to the present invention, collision inspection can be performed simply, cost-effectively, and safely, particularly by applying the above-described method according to the present invention. The machine tool system can also include (in addition to the substitute workpiece) one or more other substitute machining components, such as a substitute tool, a substitute clamping means, or a substitute tool holder. In addition to one or more machining components, the machine tool system can include both an original machining component and a substitute machining component (e.g., an original clamping means for a workpiece and an associated substitute clamping means).

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

[0067] In the embodiment shown in FIG. 1 , the substitute machining component E is attached to the machine tool 2 in the same manner as the corresponding original machining component B, and is therefore directly approached as an inspection relative position with the machine tool 2 to the relative position assigned to the inspection position. The electronic machine control device 2 a is programmed to sequentially advance to the inspection relative positions, and typically an operator manually enables transition to the next inspection relative position. The machine tool 2 stops at each inspection relative position, and the operator, typically with his bare hands, rotates the substitute workpiece 3, in FIG. 1 , about the workpiece axis WSA by the workpiece spindle 4 to check for collision positions. When the inspection relative position has been checked, the operator closes the machine cover again and can approach the next inspection relative position, and so on.

[0068] In the embodiment shown in FIGS. 1 / 2, the gas nozzle assembly 13 and the centering sensor 28 are also provided as machining components B, which are attached to the housing of the tool spindle 5 in this case. The gas nozzle assembly 13 and the centering sensor 28 are examples of auxiliary tools 27 that assist in machining the workpiece without directly participating in the machining. The gas nozzle assembly 13 allows chips to be blown away from the engagement area between the workpiece and the tool during machining. Within the scope of the collision inspection according to the present invention, the gas nozzle assembly 13 is, on the one hand, checked for collisions (especially for collisions with the workpiece / substitute workpiece 3 or its clamping means 11). On the other hand, the positioning and orientation of the gas nozzle assembly 13 (especially the three associated gas outlet openings in the illustrated example) can be optimized, for example, for the inspection position at the end of steps S2 and / or S3 and / or S4 in the above example. By only partially duplicating the workpiece with the substitute workpiece 3, this optimization is particularly easy for the operator, both in terms of accessibility and visibility of the gas nozzle assembly 13 and its parts. The centering sensor 28 detects the rotational position of the tool relative to the tool axis WZA in order to establish synchronization between the tool and the workpiece.

[0069] The substitute workpiece 3 used in the embodiment of Figure 1 is shown in isolation in Figure 3. The substitute workpiece 3 is designated as a partial workpiece 16a, and here as a half workpiece 16. In the illustrated half workpiece 16, the associated original workpiece (see Figure 5) is replicated continuously over half the circumference (i.e., a 180° inclined angle), with the remainder of the circumference omitted in the replication. The substitute workpiece 3 in Figure 3 replicates the original workpiece over its entire axial height.

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

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

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

[0073] 5 shows, for comparison, an original workpiece 20 that has been partially replicated by the alternative workpiece of FIGS. 3 and 4. This has a toothing 21, i.e., internal teeth 22.

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

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

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

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

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

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

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

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

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

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

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

[0085] Also clearly visible in Figure 11 is a typical optical gap 72 that an operator can examine to detect a collision. In Figure 11, the depicted optical gap 72 is located between the tool holder 12 and the (radially inner) contour of the substitute workpiece 3. With the relative positions of machining component B and substitute machining component E shown, no collision occurs because a sufficient optical gap 72 still remains between the substitute workpiece 3 and the tool holder 12. If, when rotating the substitute workpiece 3 or the two-dimensional template 30, the substitute workpiece 3 and the tool holder 12 come into contact (i.e., the optical gap 72 disappears), a collision exists.

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

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

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

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

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

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

[0092] In the illustrated form, the two-dimensional template 30 mounted on the template carrier 42 is selected as the multi-template 44. Here, the multi-template 44 is designed as a double template (2-fach-Schablone) with two distinct sections 55, 56 of its edge profile, each replicating the cross-sectional profile of the other workpiece. Depending on the orientation in which the multi-template 44 is assembled to the template carrier 42, the multi-template 44 functions as a substitute workpiece 3 for one or the other workpiece. In the illustrated orientation of the multi-template 44, section 56 is used for collision testing, partially replicating the cross-sectional profile of the internally toothed workpiece in the upper portion 34. In the lower portion 35, section 56 also partially replicates the clamping means, thereby simultaneously allowing the multi-template 44 to function as a substitute clamping means 29. If the template 30 of FIG. 12 were assembled to the template carrier 42 in an orientation rotated 180° about the vertical axis, section 55 would be used for collision testing.

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

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

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

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

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

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

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

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

[0101] The template 30 is formed of multiple axially (vertically in FIG. 15 ) arranged part segments 61, which can be individually adjusted in the radial direction (horizontally in FIG. 15 ). The part segments 61 are preferably formed as rods with a rectangular, particularly square, cross section. The part segments 61 are guided by inner and outer guides (inner rod carriers) 62 and 63 of the template carrier 42. The part segments 61 can be adjusted by loosening a fastening element, in this case a set screw 64, so that the entire part segments 61 (rod package, rod bundle) with their inner ends 65 approximately replicates the cross-sectional contour 66 of the desired workpiece. The set screw 64 is then tightened, thereby fixing the part segments 61 radially. The template carrier 42 is typically part of a temporary rotary holder (not shown in detail).

[0102] To facilitate engagement of the partial segments 61 by the operator, the partial segments 61 are provided at their rear ends with bends 61a, 61b, respectively, which preferably alternately point in different directions. In Figure 15, partial segments 61 having bends 61a pointing forward (out of the plane of the drawing) alternate with partial segments 61 having bends 61b pointing backward (into the plane of the drawing).

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

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

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

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

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

[0108] The light beam 67 ensures that damage to the original processing component (eg, tool) that impinges on the light beam 67 is avoided.

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

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

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

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

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

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

Claims

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

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

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

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

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

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

7. 5. The method according to claim 3, wherein for said reproduction, the substitute workpiece (3) is mounted on a work spindle (4) of the machine tool (2), and the work spindle (4) of the machine tool (2) is rotated in order to rotate the substitute workpiece (3) about the workpiece axis (WSA).

8. 5. The method according to claim 1, wherein for the reproduction, the substitute workpiece (3) is assembled on a temporary rotating holder (41), and for rotating the substitute workpiece (3), the substitute workpiece (3) is rotated on the temporary rotating holder (41).

9. The substitute workpiece (3) has an axial partial region (17) in which the workpiece (20) is replicated over only a portion of the circumference of the workpiece (20), and an axial remaining region (18) in which the workpiece (20) is replicated over the entire circumference thereof; In particular, in the axial partial region (17), the part of the circumference has partial structures (19) spaced apart from one another in the circumferential direction. The method according to any one of claims 1 to 4, characterized in that

10. the replacement workpiece (3) is formed as a partial workpiece (16a) which the workpiece (20) replicates over at least one-third of the circumference and at most two-thirds of the circumference at least in an axial partial region (17), In particular, the partial workpiece (16a) is formed as a half workpiece (16). The method according to any one of claims 1 to 4, characterized in that

11. The method according to any one of claims 1 to 4, characterized in that the substitute workpiece (3) fully or partially replicates only the cross-sectional contour (66) of the workpiece (20).

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

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

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

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

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

17. The one or more substitute machining components (E) include a substitute tool (14) that is a copy or partial copy of the tool (7). The method according to any one of claims 1 to 4, characterized in that

18. the substitute tool (14) is a partial copy of the tool (7), and in the substitute tool (14), the tool (7) is copied over at least an axial partial area and over only a portion of the circumference of the tool (7); In the reproduced relative position, the substitute tool (14) is rotated around the tool axis (WZA).

18. The method of claim 17, wherein:

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

20. 5. The method according to any one of claims 1 to 4, characterized in that the one or more alternative machining components (E) comprise alternative clamping means (29) that are a replica or partial replica of clamping means (11) used to hold the workpiece (20) on a work spindle (4) of the machine tool (2).

21. the replacement clamping means (29) is rotated together with the replacement workpiece (3) in the recreated relative position; In particular, the alternative clamping means (29) and the alternative workpiece (3) are formed by a common two-dimensional template (30).

21. The method of claim 20, wherein:

22. 5. The method according to claim 1, wherein in one or more alternative machining components (E), the toothings (7a; 21) of the corresponding machining component (B) are wholly or partly replaced by the envelopes (38, 39; 75) or surfaces (23, 24) of the toothings (7a; 21).

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

24. 5. The method according to claim 1, wherein for collision checking, at least one optical gap (72) is observed when rotating the substitute workpiece (3).

25. the one or more alternative processing components (E) include at least one alternative processing component (E) having a first replicated section (36) and a second replicated section (37), the replicated sections (36, 37) replicating two similarly formed sections of the corresponding processing component (B), the type of replication being different between the first replicated section (36) and the second replicated section (37); In particular, the same sections of the machined component carry teeth (7a; 21), the first replica section (36) replicating the tip circle of the teeth (7a; 21) and the second replica section (37) replicating the root circle of the teeth (7a; 21). The method according to any one of claims 1 to 4, characterized in that

26. 5. The method according to claim 1, wherein at least one boundary marking (40) is applied to at least one alternative fabricated component (E), said boundary marking indicating boundaries of the structure of said associated fabricated component (B) that are not or not completely replicated in said alternative fabricated component (E).

27. an identification marking (33) is applied to at least one alternative processing component (E), said identification marking allowing identification of said alternative processing component (E) and / or allocation of said alternative processing component (E) to said corresponding processing component (B); In particular, said identification marking (33) is human readable and / or machine readable; In particular, said identification marking (33) comprises an alphanumeric code (32) and / or a QR code and / or a bar code and / or an RFID tag (31). The method according to any one of claims 1 to 4, characterized in that

28. 5. The method according to claim 1, wherein the machining component (B) comprises at least one auxiliary tool (27), in particular the at least one auxiliary tool (27) comprises a gas nozzle assembly (13; 91) and / or a suction nozzle assembly and / or a cooling lubricant nozzle assembly and / or a centering sensor (28; 93).

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

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

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

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

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

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