Gear cutting machine and phase alignment method thereof

Abstract

To provide a gear processing machine which can minimize addition of components used in phase detection and adjust phases of a workpiece and a tool while preventing errors resulting from manual work.SOLUTION: A structure of a gear processing machine 100 of the invention includes: a workpiece spindle 110 which rotates an attached workpiece 102; a tool spindle 120 which rotates an attached tool 104; a laser sensor 130 attached to a side surface of the tool spindle 120; a sensor rotation device 140 which rotates the laser sensor 130 along an axial direction of the tool spindle 120; an angle control unit 152 which controls a rotation angle of the sensor rotation device 140; and a phase detection part 154 which detects phases of the workpiece 102 and the tool 104.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a gear cutting machine that cuts gears by rotating a tool and a workpiece synchronously, and a phase matching method for the same. [Background technology]

[0002] In a gear cutting machine, when a tool, for example, a cutter and a workpiece are rotated synchronously to machine a gear, it is necessary to align the phases of the cutter and the workpiece. For example, Patent Document 1 discloses a phase alignment method for a gear cutting machine, which "uses a gear cutting machine equipped with a tool spindle that drives the cutter, a workpiece spindle that drives the workpiece, a cutter phase measurement unit that detects the phase of the cutter, and a workpiece phase measurement unit that detects the phase of the workpiece, attaches a dummy cutter that is tougher and lower in hardness than the cutter, measures the phase, engages the dummy cutter with the workpiece to align them, replaces the dummy cutter with the cutter, measures the phase, and corrects the phase of the cutter based on the phase of the dummy cutter." [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Patent Application No. 2021-146366 Summary of the Invention [Problem to be solved by the invention]

[0004] However, the technology of Patent Document 1 requires dedicated sensors and drive devices for detecting the phase of the workpiece and the tool, respectively, and also requires a dummy cutter. Another technique used for phasing gear cutting machines is to attach a laser sensor to the tool spindle to detect the phase of the workpiece. In this method, a tool whose phase has been adjusted in advance outside the machine is mounted on the actual machine. However, this method requires manual intervention when an operator mounts a tool whose phase has been adjusted in advance on the actual machine, which can lead to installation errors, setup mistakes, and installation errors.

[0005] In view of the above circumstances, an object of the present invention is to provide a gear cutting machine and a phase adjustment method therefor that are capable of adjusting the phases of both the workpiece and the tool while minimizing the number of additional parts used for phase detection and preventing errors that may result from manual work. [Means for solving the problem]

[0006] In order to solve the above problems, a typical configuration of a gear cutting machine of the present invention includes a work spindle that rotates an attached workpiece, a tool spindle that rotates an attached tool, a laser sensor attached to the side of the tool spindle, a sensor rotation device that rotates the laser sensor along the axial direction of the tool spindle, an angle control unit that controls the rotation angle of the sensor rotation device, and a phase detection unit that detects the phases of the workpiece and the tool.

[0007] The phase detection section may detect the phase of the tool by detecting peaks while rotating the laser sensor along the axial direction of the tool using a sensor rotation device.

[0008] In order to solve the above problems, a representative configuration of the phase alignment method for a gear cutting machine of the present invention is a method for aligning the phase of a gear cutting machine including a work spindle that rotates the workpiece, a tool spindle that rotates the tool, a laser sensor attached to the side of the tool spindle, a sensor rotating device that rotates the laser sensor in the axial direction of the tool spindle, and an angle control unit that controls the rotation angle of the sensor rotating device, wherein the angle control unit controls the rotation angle so that the laser sensor is directed toward the workpiece to detect the phase of the workpiece, and the angle control unit controls the rotation angle so that the laser sensor is directed toward the tool to detect the phase of the tool, thereby aligning the phases of the workpiece and the tool. [Effects of the Invention]

[0009] According to the present invention, it is possible to provide a gear cutting machine and a phase adjustment method thereof that are capable of adjusting the phases of both the workpiece and the tool while minimizing the addition of parts used for phase detection and preventing errors that may result from manual work. [Brief explanation of the drawings]

[0010] [Figure 1] FIG. 1 is a diagram illustrating a gear cutting machine according to an embodiment of the present invention. [Figure 2] FIG. 2 is a diagram illustrating a state in which a laser sensor of the gear cutting machine in FIG. 1 is moved from an initial position to a rotated position. [Figure 3] 3 is a diagram illustrating a rotational position of a laser sensor different from that in FIG. 2 in the gear cutting machine of FIG. 1. FIG. [Figure 4] FIG. 2 is a diagram illustrating a state in which a laser sensor is placed at a standby position in the gear cutting machine of FIG. 1. [Figure 5] FIG. 2 is a diagram illustrating a tool attached to a tool spindle in the gear cutting machine of FIG. 1. [Figure 6] 4 is a flowchart illustrating a phase alignment method for a gear cutting machine according to the present embodiment. [Figure 7] 6 is a flowchart illustrating a method for detecting the phase of a tool when the tool used in the gear cutting machine of FIG. 1 is the skiving cutter of FIG. 5(a). [Figure 8] 6 is a flowchart illustrating a method for detecting the phase of a tool when the tool used in the gear cutting machine of FIG. 1 is the hob cutter of FIG. 5(b). DETAILED DESCRIPTION OF THE INVENTION

[0011] Preferred embodiments of the present invention will be described in detail below with reference to the accompanying drawings. Dimensions, materials, and other specific values ​​shown in the embodiments are merely examples for facilitating understanding of the invention and, unless otherwise specified, do not limit the present invention. In this specification and drawings, elements having substantially the same functions and configurations are designated by the same reference numerals to avoid redundant explanation, and elements not directly related to the present invention are not shown.

[0012] Fig. 1 is a diagram illustrating a gear cutting machine according to this embodiment, illustrating a state in which a laser sensor 130 is arranged at an initial position P0. Fig. 2 is a diagram illustrating a state in which the laser sensor of the gear cutting machine of Fig. 1 has been moved from the initial position P0 to a rotation position P1. Fig. 3 is a diagram illustrating a rotation position P2 of the laser sensor in the gear cutting machine of Fig. 1, which is different from that in Fig. 2. Fig. 4 is a diagram illustrating a state in which the laser sensor is arranged at a standby position P3 in the gear cutting machine of Fig. 1.

[0013] The gear cutting machine of this embodiment shown in Figures 1 to 4 is a device that cuts gears by synchronously rotating a workpiece 102 and a tool 104. The gear cutting machine 100 has a workpiece spindle 110 that rotates the workpiece 102, and a tool spindle 120 that rotates the tool 104. The workpiece 102 is attached to the workpiece spindle 110, and the tool 104 is attached to the tool spindle 120, both of which are interchangeable.

[0014] Fig. 5 is a diagram illustrating a tool attached to the tool spindle of the gear cutting machine of Fig. 1. Examples of the tool 104 attached to the tool spindle 120 (see Figs. 1 to 4) include a skiving cutter 104a shown in Fig. 5(a) and a hob cutter 104b shown in Fig. 5(b).

[0015] The skiving cutter 104a shown in Fig. 5(a) has multiple blades 106a arranged in a gear shape in the rotational direction of the tool spindle 120. The hob cutter 104b shown in Fig. 5(b) has blades 106b arranged in a screw shape in the tool length direction. The hob cutter 104b also has grooves 108 formed therein to allow chips and powder generated during machining to escape to the outside.

[0016] A feature of this embodiment is that the gear cutting machine 100 includes a laser sensor 130, a sensor rotating device 140, and a control unit 150 that controls the operation of the gear cutting machine 100. The laser sensor 130 is a distance measurement sensor that is a phase detection sensor attached to the side surface of the tool spindle 120. The sensor rotating device 140 rotates the laser sensor 130 along the axial direction of the tool spindle 120.

[0017] In this embodiment, the control unit 150 functions as an angle control unit 152 and a phase detection unit 154. The angle control unit 152 controls the rotation angle of the sensor rotation device 140. The phase detection unit 154 detects the phases of the workpiece 102 and the tool 104 by directing the laser sensor 130 toward the workpiece 102 and the tool 104 through rotation angle control by the angle control unit 152.

[0018] Fig. 6 is a flowchart illustrating a phase alignment method for a gear cutting machine according to this embodiment. In the alignment method for a gear cutting machine according to this embodiment, as shown in Fig. 6, first, the control unit 150 functions as a phase detection unit, and controls the rotation angle of the laser sensor 130 using the angle control unit 152, causing the laser sensor 130 to irradiate a laser beam toward the workpiece 102 (S202). For example, if the laser sensor 130 is at the initial position P0 in Fig. 1, the angle control unit 152 controls the rotation angle drive of the sensor rotating device 140, causing the laser sensor 130 to rotate along the axial direction of the tool spindle 120 to the rotation position P1 in Fig. 2.

[0019] Then, the control unit 150 rotates the workpiece 102 while the laser is being irradiated (S204), and the phase detection unit 154 detects the phase of the workpiece 102 (S206). Subsequently, the phase detection unit 154 detects the phase of the tool 104 (S208).

[0020] (Tool phase detection: When the tool 104 is the skiving cutter 104a) Fig. 7 is a flowchart illustrating a method for detecting the phase of a tool when the tool used in the gear cutting machine of Fig. 1 is the skiving cutter of Fig. 5(a). When detecting the tool phase, first, as shown in Fig. 7, the phase detection unit 154 rotates the laser sensor 130 using the sensor rotating device 140 (S222).

[0021] For example, when the laser sensor 130 is at the initial position P0 in Fig. 1, the angle control unit 152 controls the rotation angle of the sensor rotation device 140, and the sensor rotation device 140 rotates the laser sensor 130 along the axial direction of the tool spindle 120 to a rotation position P2 in Fig. 3. Then, the control unit 150 controls the laser sensor 130 to irradiate a laser beam toward a predetermined position (the position of the blade 106a) based on the tool specifications of the tool 104 (skiving cutter 104a) (S224). That is, when the tool 104 is the skiving cutter 104a, the laser beam is irradiated in one direction D1 (the direction of the predetermined position (the position of the blade 106a)) as shown in Fig. 5(a).

[0022] Next, the control unit 150 rotates the tool 104 (skiving cutter 104a) while the laser is being irradiated (S226). If a predetermined peak is detected by the laser irradiation (YES in S228), the phase detection unit 154 detects the phase of the tool 104 (S230). If the predetermined peak is not detected by the laser irradiation (NO in S228), the phase detection unit 154 detects an abnormality, such as the predetermined tool not being attached to the tool spindle 120 (S232).

[0023] (Tool phase detection: When the tool 104 is the hob cutter 104b) Fig. 8 is a flowchart illustrating a method for detecting the phase of a tool when the tool used in the gear cutting machine of Fig. 1 is the hob cutter of Fig. 5(b). In Fig. 8, operations common to Fig. 7 are assigned the same reference numerals and will not be described again.

[0024] 8, the laser sensor 130 is rotated (S222), and a laser is emitted toward a predetermined position on the side of the hob 104b (S224). The predetermined position may be anywhere within the range of the blade 106b. The hob 104b is rotated (S226), and when a predetermined peak is detected (YES in S228), the phase detection unit 154 detects the phase of the tool 104 (S230).

[0025] If the predetermined peak is not detected by irradiating the laser (NO in S228), there is a possibility that the peak position overlaps with the position of the groove 108. Therefore, the angle control unit 152 controls the rotation angle of the sensor rotation device 140, and the sensor rotation device 140 rotates the laser sensor 130 along the axial direction of the tool. Then, the phase detection unit 154 irradiates the tool 104 (hob cutter 104b) with a laser while the laser sensor 130 is rotating (S242).

[0026] That is, in the phase alignment method for the gear cutting machine 100 of this embodiment, in S242, peaks are detected while changing the irradiation direction of the laser sensor 130 in the tool length direction of the tool 104 (hob 104b) (laser scanning). Specifically, the irradiation direction of the laser sensor 130 is changed to directions D2, D3, and D4 as shown in Fig. 5(b). Note that the hob 104b is not rotated while the laser is scanning in the tool length direction.

[0027] If a peak is detected in the laser scan (YES in S244), the control unit 150 returns to the operation of S224 and rotates the hob 104b to detect the phase of the tool (S230).If a peak is not detected in the laser scan (NO in S244), the phase detection unit 154 detects an abnormality, such as the tool spindle 120 not having a specified tool attached (S246).

[0028] When scanning the laser in the tool length direction, there is a possibility that the laser may be scanned onto the groove 108 of the hob 104b. Therefore, even if no peak is detected (NO in S244), it is not necessary to immediately detect an abnormality (S246), but the angle of the hob 104b may be changed and laser scanning may be performed again in the tool length direction (S242).

[0029] 7 and 8, after detecting the phase of the tool 104 (skiving cutter 104a or hob cutter 104b), the control unit 150 aligns the phase of the workpiece 102 with that of the tool 104. When machining the workpiece 102 using the tool 104 thereafter, the laser sensor 130 is moved to the standby position P3 (which may be the same as the initial position P0) in FIG.

[0030] As described above, the gear cutting machine 100 and the phase alignment method of this embodiment are provided with one laser sensor 130 and one sensor rotating device 140 for rotating the laser sensor 130, and the laser sensor 130 is rotated by the sensor rotating device 140. This makes it possible to detect the phases of both the workpiece 102 and the tool 104 and to align their phases.

[0031] According to the above configuration, it is possible to minimize the number of additional parts used for phase detection, and to obtain the above-mentioned effects while suppressing increases in device costs. Furthermore, since no manual work is required when detecting the phases of the workpiece 102 and the tool 104, it is possible to prevent errors caused by manual work.

[0032] Furthermore, with the gear cutting machine 100 of this embodiment, the phase of the hob cutter 104b in addition to the skiving cutter 104a can be detected by irradiating the tool with a laser while rotating the laser sensor 130 in the tool length direction. This widens the range of application of phase detection, allowing for the use of standardized parts and reducing equipment costs.

[0033] While the preferred embodiments of the present invention have been described above with reference to the accompanying drawings, it goes without saying that the present invention is not limited to such examples. It is clear that those skilled in the art can conceive of various modifications and alterations within the scope of the claims, and it is understood that these modifications and alterations also fall within the technical scope of the present invention. [Industrial Applicability]

[0034] The present invention can be used in a gear cutting machine that cuts a gear by rotating a tool and a workpiece synchronously, and a phase matching method for the gear cutting machine. [Explanation of symbols]

[0035] 100... gear cutting machine, 102... workpiece, 104... tool, 104a... skiving cutter, 104b... hob cutter, 106a... blade, 106b... blade, 108... groove, 110... work spindle, 120... tool spindle, 130... laser sensor, 140... sensor rotation device, 150... control unit, 152... angle control unit, 154... phase detection unit

Claims

1. a work spindle that rotates the attached workpiece; a tool spindle for rotating an attached tool; a laser sensor attached to a side of the tool spindle; a sensor rotating device that rotates the laser sensor along the axial direction of the tool spindle; an angle control unit that controls a rotation angle of the sensor rotation device; a phase detection unit that detects a phase of the workpiece and the tool; Equipped with a gear cutting machine, characterized in that the phase detection unit detects peaks while rotating the laser sensor along the axial direction of the tool using the sensor rotation device, thereby detecting the phase of the tool.

2. A phase alignment method for a gear cutting machine including a work spindle that rotates a workpiece, a tool spindle that rotates a tool, a laser sensor attached to a side surface of the tool spindle, a sensor rotating device that rotates the laser sensor along an axial direction of the tool spindle, and an angle control unit that controls a rotation angle of the sensor rotating device, The angle control unit controls the rotation angle to direct the laser sensor toward the workpiece, thereby detecting the phase of the workpiece; detecting a peak while rotating the laser sensor along the axial direction of the tool by rotation angle control by the angle control unit, and detecting a phase of the tool; A phase alignment method for a gear cutting machine, comprising: aligning the phases of the workpiece and the tool.

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