Machining load determination system

Abstract

This invention provides a system which increases a detection precision of a difference between simulation and actual machining without limiting a precision of the simulation. This machining load determination system comprises: an actual machining unit which includes a movable unit provided with a tool or a workpiece; a simulation unit which has a virtual space including a virtual tool, a virtual workpiece, and a virtual movable unit; a virtual load acquisition unit which acquires information relating to a virtual load occurring to the virtual movable unit; an actual load acquisition unit which acquires information relating to an actual load occurring to the movable unit; and a load information determination unit which determines whether or not a difference exists between the virtual load information and the actual load information. The simulation unit calculates the virtual load information and comparison position specification data which specifies a position for comparing the virtual load information and the actual load information with each other. The virtual load acquisition unit acquires the virtual load information in association with the comparison position specification data. The actual load acquisition unit acquires the actual load information in association with the comparison position specification data. The load information determination unit compares the virtual load information and the actual load information with each other on the basis of the comparison position specification data.

Description

Technical Field

[0001] The present disclosure relates to a processing load determination system.

Background Art

[0002] There are industrial machines (for example, machine tools, electric discharge machining machines, etc.) that have a movable part provided with a tool or a workpiece, and perform machining of the workpiece by relatively moving the tool and the workpiece. In such industrial machines, there is a technique of performing a machining simulation using a virtual space in which an environment similar to the actual machining environment is reproduced in a three-dimensional model, and checking whether there is a problem in operation data (for example, a machining program).

[0003] In such a technique, due to various factors, there may be an unintended difference between the three-dimensional model of the virtual space defined for simulation and the actual environment. Examples of various factors include, for example, the workpiece floating during machining in the actual environment, and forgetting to reflect tool wear correction in the three-dimensional model of the virtual space. In this case, there may be a difference between the result obtained by simulation and the result obtained in actual machining.

[0004] Regarding this point, Patent Document 1 discloses a technique of arranging a real machine part and a simulation part in parallel, inputting the same command to the real machine part and the simulation part, comparing the internal state quantities of the real machine part and the simulation part, and comparing the internal state quantity comparison value with a preset detection threshold value to detect that the movable part contacts or collides with another object. It is considered that this technique can detect whether there is a difference between the result obtained by simulation and the result obtained in actual machining. In addition, Patent Document 1 discloses that the arithmetic expression of the model of the simulation part is simple and the processing time is short.

Prior Art Documents

Patent Documents

[0005] [Patent Document 1] Japanese Patent Publication No. 2004-364396 [Overview of the Initiative] [Problems that the invention aims to solve]

[0006] In the technology disclosed in Patent Document 1, the simulation unit needs to perform the simulation in real time in accordance with the operation of the actual machine unit. The processing time for simulations using a 3D model as a virtual space is relatively long. Therefore, in the technology disclosed in Patent Document 1, as described above, the calculation formula of the model in the simulation unit is simplified to shorten the processing time in accordance with the operation time of the actual machine unit.

[0007] Thus, real-time simulations of actual machining processes have limited accuracy. As a result, it may not be possible to correctly detect the differences between the simulation and the actual machining process. Therefore, it is desirable to improve the accuracy of detecting differences between simulations and actual machining, without limiting the accuracy of the simulations themselves. [Means for solving the problem]

[0008] The machining load determination system of this disclosure comprises: an actual machining unit having a movable part on which a tool or workpiece is provided, and which performs machining on the workpiece by relatively moving the tool and the workpiece based on operating data; a simulation unit that performs machining simulation on a virtual workpiece by relatively moving the virtual tool and the virtual workpiece based on the operating data in a virtual space including a virtual tool, a virtual workpiece, and a virtual movable part corresponding to the tool, the workpiece, and the movable part, respectively; a virtual load acquisition unit that acquires virtual load information generated on the virtual movable part obtained by the machining simulation by the simulation unit; an actual load acquisition unit that acquires actual load information generated on the movable part obtained by machining by the actual machining unit; and a load information determination unit that compares the virtual load information and the actual load information and determines whether or not there is a difference between the information. The simulation unit calculates the virtual load information and comparison point identification data that identifies the comparison points between the virtual load information and the actual load information. The virtual load acquisition unit acquires the virtual load information in association with the comparison point identification data. The actual load acquisition unit acquires the actual load information in association with the comparison point identification data. The load information determination unit compares the virtual load information and the actual load information based on the comparison point identification data. [Brief explanation of the drawing]

[0009] [Figure 1] This figure shows an overview of the industrial machinery system according to this embodiment. [Figure 2] This figure shows the configuration of the processing load determination system according to this embodiment. [Figure 3A] This figure shows an example of virtual load information and data used to identify comparison points. [Figure 3B] This figure shows an example of actual load information and data used to identify comparison points. [Figure 4A] This figure shows Example 1 of the machining load determination process using the machining load determination system according to this embodiment (when there is no difference between the actual machining part and the simulation part). [Figure 4B]This figure shows Example 1 of the machining load determination process by the machining load determination system according to this embodiment (in the case of a difference between the actual machining part and the simulation part: a pattern in which contact is detected only in the simulation part). [Figure 4C] This figure shows Example 1 of the machining load determination process by the machining load determination system according to this embodiment (in the case of a difference between the actual machining part and the simulation part: a pattern in which contact is detected only in the actual machining part). [Figure 4D] This figure shows Example 1 of the machining load determination process by the machining load determination system according to this embodiment (in the case of a difference between the actual machining part and the simulation part: a pattern in which the workpiece lifts up). [Figure 5A] This figure shows Example 2 of the machining load determination process using the machining load determination system according to this embodiment (when there is no difference between the actual machining part and the simulation part). [Figure 5B] This figure shows Example 2 of the machining load determination process using the machining load determination system according to this embodiment (in the case of a difference between the actual machining part and the simulation part: a pattern in which contact is detected only in the simulation part). [Figure 5C] This figure shows Example 2 of the machining load determination process by the machining load determination system according to this embodiment (in the case of a difference between the actual machining part and the simulation part: a pattern in which contact is detected only in the actual machining part). [Figure 6A] This figure shows Example 3 of the machining load determination process using the machining load determination system according to this embodiment (when there is no difference between the actual machining part and the simulation part). [Figure 6B] This figure shows Example 3 of the machining load determination process using the machining load determination system according to this embodiment (in the case of a difference between the actual machining part and the simulation part: a pattern in which contact is detected only in the simulation part). [Figure 6C] This figure shows Example 3 of the machining load determination process by the machining load determination system according to this embodiment (in the case of a difference between the actual machining part and the simulation part: a pattern in which contact is detected only in the actual machining part). [Figure 7]This is a diagram showing Example 4 of the processing load determination process by the processing load determination system according to this embodiment. [Figure 8] This is a diagram showing Example 5 of the processing load determination process by the processing load determination system according to this embodiment.

Mode for Carrying Out the Invention

[0010] Hereinafter, an example of this embodiment will be described with reference to the accompanying drawings. In each drawing, the same or corresponding parts will be given the same reference numerals.

[0011] [Outline of Industrial Machine System] First, the outline of the industrial machine system according to this embodiment will be described. FIG. 1 is a diagram showing the outline of the industrial machine system according to this embodiment. As shown in FIG. 1, the industrial machine system 100 includes a numerical control device 110, a drive unit 120, and a machine tool (industrial machine) 130.

[0012] The machine tool 130 is a machining part described later, and performs machining to remove the workpiece W by relatively moving the tool T and the workpiece (workpiece to be machined) W based on the operation data. Hereinafter, an M-series (machining center series) machine will be exemplified as the machine tool, but this embodiment is not limited thereto. This embodiment is also applicable to a T-series (lathe series) machine tool. Further, hereinafter, a machine tool will be exemplified as the industrial machine, but this embodiment is not limited thereto. This embodiment is also applicable to various industrial machines in which the tool T and the workpiece W come into contact to perform machining of the workpiece W, such as an electric discharge machining machine.

[0013] The machine tool 130 includes a motor 132, a tool mounting portion 134, and a table 136. The mounting portion 134 or the table 136 is a movable part. The tool T is attached to the mounting portion 134, and the workpiece W is provided on the table 136.

[0014] The motor 132 is a motor for feeding the attachment part 134 or the movable part of the table 136, that is, the tool T or the workpiece W, and may include a plurality of motors for, for example, X-axis movement, Y-axis movement, and Z-axis movement. The motor 132 is driven by the drive unit 120.

[0015] The numerical control device 110 generates a position command along the relative movement path of the tool T with respect to the workpiece W in the machine tool 130 based on the machining program.

[0016] The drive unit 120 drives the motor 132 in the machine tool 130 based on the position command from the numerical control device 110. The drive unit 120 may include a plurality of drive units for each motor (for example, the X-axis motor, the Y-axis motor, the Z-axis motor) of the machine tool 130. The drive unit 120 is, for example, a servo control unit, and performs drive control of the motor 132 based on the position command and the position feedback detected by an encoder provided in the motor 132.

[0017] [Machining Load Determination System] FIG. 2 is a diagram showing the configuration of the machining load determination system according to the present embodiment. As shown in FIG. 2, the machining load determination system 10 includes an actual machining unit 12, a simulation unit 14, an actual load acquisition unit 16, a virtual load acquisition unit 18, a storage unit 20, a load information determination unit 22, an operation control unit 24, a correction unit 26, and a display unit 28.

[0018] The actual machining unit 12 is the machine tool 130 described above. As described above, the actual machining unit 12 uses the attachment part 134 provided with the tool T or the table 136 provided with the workpiece W as a movable part, and performs machining of the workpiece W by relatively moving the tool T and the workpiece W based on operation data.

[0019] The simulation unit 14 may be provided in the numerical control device 110 described above, or it may be configured by a computer different from the numerical control device 110. The simulation unit 14 includes a virtual space VS that includes virtual tools Ts, virtual workpieces Ws, virtual mounting parts (virtual movable parts) 134s, and a table (virtual movable part) 136s, which simulate the tool T, workpiece W, mounting part (movable part) 134, and table (movable part) 136 in the actual machining unit 12, respectively. In the virtual space VS, the simulation unit 14 performs a machining simulation of the virtual workpiece Ws by relatively moving the virtual tool Ts and virtual workpiece Ws based on the operation data. As shown in Figure 3A, the simulation unit 14 calculates virtual load information generated in the virtual movable parts 134s and 136s, and comparison point identification data that identifies the comparison points between the virtual load information and the actual load information. Details of the virtual load information and comparison point identification data will be described later.

[0020] The actual load acquisition unit 16 is provided in the drive unit (servo control unit) 120 described above. As shown in Figure 3B, the actual load acquisition unit 16 acquires actual load information generated on the movable parts 134 and 136, obtained by machining by the actual machining unit 12. Specifically, the actual load acquisition unit 16 acquires virtual load information in association with comparison point identification data. Details of the actual load information and comparison point identification data will be described later.

[0021] The virtual load acquisition unit 18 may be provided in the numerical control device 110 described above, or in the computer constituting the simulation unit 14, or it may be configured by a computer different from the numerical control device 110 and the simulation unit 14. As shown in Figure 3A, the virtual load acquisition unit 18 acquires virtual load information generated in the virtual movable parts 134s and 136s obtained by the machining simulation by the simulation unit 14. Specifically, the virtual load acquisition unit 18 acquires the virtual load information in association with comparison point identification data.

[0022] The load information determination unit 22 may be provided in the numerical control device 110 described above, or in the drive unit (servo control unit) 120, or it may be configured by a computer different from the numerical control device 110 and the drive unit 120. Based on the comparison point identification data, the load information determination unit 22 compares the virtual load information and the actual load information and determines whether or not there is a difference between the two pieces of information. That is, the load information determination unit 22 determines whether or not there is a difference between the load information of the movable parts 134 and 136 in the actual machining unit 12 and the load information of the virtual movable parts 134s and 136s in the simulation unit 14.

[0023] The motion control unit 24 is provided in the drive unit (servo control unit) 130 described above. If the load information determination unit 22 determines that there is a difference between the virtual load information and the actual load information, the motion control unit 24 will perform at least one of the following actions in the actual machining unit 12: limiting the output for operating the movable parts 134 and 136 (for example, torque limiting), retracting the movable parts 134 and 136 as set in the machining program, or immediately slowing down and stopping the operation of the movable parts 134 and 136.

[0024] The correction unit 26 may be provided in the numerical control device 110 described above, or it may be configured by a computer different from the numerical control device 110. If the load information determination unit 22 determines that there is a difference between the virtual load information and the actual load information, the correction unit 26 changes (corrects) the preconditions for the machining simulation in the simulation unit 14, for example, the preconditions for the virtual tool Ts, virtual workpiece Ws, and virtual movable parts 134s and 136s in the operation data.

[0025] The simulation unit 14, the actual load acquisition unit 16, the virtual load acquisition unit 18, the load information determination unit 22, the operation control unit 24, and the correction unit 26 described above are composed of, for example, arithmetic processors such as a CPU (Central Processing Unit), a DSP (Digital Signal Processor), and an FPGA (Field-Programmable Gate Array). The various functions of the simulation unit 14, the actual load acquisition unit 16, the virtual load acquisition unit 18, the load information determination unit 22, the operation control unit 24, and the correction unit 26 are realized, for example, by executing predetermined software (programs) stored in the memory unit 20. The various functions of the simulation unit 14, the actual load acquisition unit 16, the virtual load acquisition unit 18, the load information determination unit 22, the operation control unit 24, and the correction unit 26 may be realized through the cooperation of hardware and software, or they may be realized by hardware (electronic circuits) alone.

[0026] The storage unit 20 is composed of memory such as ROM (Read Only Memory), HDD (Hard Disk Drive), or SSD (Solid State Drive). The storage unit 20 stores predetermined software (programs) that realize various functions of the simulation unit 14, the actual load acquisition unit 16, the virtual load acquisition unit 18, the load information determination unit 22, the operation control unit 24, and the correction unit 26. The storage unit 20 also stores virtual load information and comparison location identification data shown in Figure 3A, acquired by the virtual load acquisition unit 18, and actual load information and comparison location identification data shown in Figure 3B, acquired by the actual load acquisition unit 16.

[0027] The display unit 28 is composed of, for example, a liquid crystal display or an organic EL display. The display unit 28 displays the comparison point identification data, which the load information determination unit 22 has determined to have a difference between virtual load information and actual load information, in a different display mode according to the difference. For example, in the program (operation data), the display unit 28 highlights and displays blocks corresponding to the comparison point identification data, which has been determined to have a difference between virtual load information and actual load information, in a different display mode (e.g., color, blinking, etc.) than blocks that do not have a difference.

[0028] Next, with reference to Figures 4A to 8, some examples of the machining load determination process by the machining load determination system 10 described above will be explained. Figures 4A to 4D are diagrams showing Example 1 of the machining load determination process by the machining load determination system according to this embodiment, Figures 5A to 5C are diagrams showing Example 2 of the machining load determination process by the machining load determination system according to this embodiment, and Figures 6A to 6C are diagrams showing Example 3 of the machining load determination process by the machining load determination system according to this embodiment. Figure 7 is a diagram showing Example 4 of the machining load determination process by the machining load determination system according to this embodiment, and Figure 8 is a diagram showing Example 5 of the machining load determination process by the machining load determination system according to this embodiment.

[0029] [Example 1] In Example 1, the elapsed time of program operation (time information) is used as the data for identifying the comparison point. Figure 4A shows the case where there is no difference between the actual load information of the movable part in the actual machining area and the virtual load information of the virtual movable part in the simulation area. Figure 4B shows the case where there is a difference between the actual load information of the movable part in the actual machining area and the virtual load information of the virtual movable part in the simulation area (a pattern in which contact is detected only in the simulation area). Figure 4C shows the case where there is a difference between the actual load information of the movable part in the actual machining area and the virtual load information of the virtual movable part in the simulation area (a pattern in which contact is detected only in the actual machining area). Figure 4D shows the case where there is a difference between the actual load information of the movable part in the actual machining area and the virtual load information of the virtual movable part in the simulation area (a pattern in which the workpiece lifts up).

[0030] (If there is no difference between the actual machining part and the simulation part) <1-1> As shown in Figure 4A, for example, the numerical control device 110 analyzes the machining program and creates time-series data Xs(0), Xs(1) to Xs(n) of the machine coordinates Xs(i) of the virtual movable parts 134s and 136s from the start time Ts(0) to time Ts(i) seconds later as operating data for the simulation unit 14, and outputs it to the simulation unit 14. Also, for example, the numerical control device 110 analyzes the machining program and creates time-series data Xr(0), Xr(1) to Xr(n) of the machine coordinates Xr(j) of the movable parts 134 and 136 from the start time Tr(0) to time Tr(j) seconds later as operating data for the actual machining unit 12, and outputs it to the drive unit 120. Here, i and j are any integers from 1 to n. n is an integer greater than or equal to 1. Xs(i) and Xr(j) are q-dimensional arrays, where the machine coordinates of the p-th axis of the virtual movable part can be represented by Xsp(i) and the machine coordinates of the p-th axis of the movable part can be represented by Xrp(j). q is an integer greater than or equal to 1 and indicates the number of axes of the machine. p is any integer from 1 to q.

[0031] In this embodiment, the numerical control device 110 is shown as an example in which it analyzes the machining program and creates time-series data (operation data) of machine coordinates. However, this embodiment is not limited to this, and a computer constituting the simulation unit 14 or another computer may analyze the machining program and create time-series data (operation data) of machine coordinates.

[0032] <1-2> The simulation unit 14 performs a machining simulation of the virtual workpiece Ws by relatively moving the virtual tool Ts and the virtual workpiece Ws based on the machine coordinates Xs(0) to Xs(n) (operation data) output from the numerical control device 110.

[0033] The simulation unit 14 calculates contact information indicating whether or not the virtual tool Ts and the virtual workpiece Ws are in contact, as virtual load information occurring at a certain machine coordinate Xs(i) at a certain time Ts(i) in the virtual movable parts 134s and 136s. For example, the simulation unit 14 sets the contact flag to 0 if the virtual tool Ts is outside the virtual workpiece Ws, and sets the contact flag to 1 if the virtual tool Ts moves from outside to inside the virtual workpiece Ws.

[0034] Furthermore, the simulation unit 14 calculates a certain time Ts(i) as comparison point identification data to identify the comparison point between virtual load information and actual load information. Specifically, the comparison point identification data is data that associates the virtual load information and actual load information in terms of time series or machining position. More specifically, the comparison point identification data is data that creates a one-to-one correspondence between the time Ts(i) when the virtual tool Ts and virtual workpiece Ws come into contact in the simulation unit 14 and the time Tr(j) when the tool T and workpiece W come into contact in the actual machining unit 12. In other words, the comparison point identification data is data that identifies time Ts(i) and time Tr(j) as the comparison point between virtual load information and actual load information. As a result, the load information determination unit 22 can appropriately compare the virtual load information at time Ts(i) and the actual load information at time Tr(j) based on the comparison point identification data. As mentioned above, the simulation unit 14 may be provided in the numerical control device 110, or it may be configured by a computer different from the numerical control device 110.

[0035] As shown in Figure 4A, the numerical control device 110 (virtual load acquisition unit 18) acquires contact flags 0 / 1 (virtual load information) in association with time Ts(i) (comparison location identification data).

[0036] The simulation unit 14 performs the above-mentioned machining simulation before the actual machining unit 12 operates based on the operating data, and pre-calculates virtual load information and comparison location data. Alternatively, the virtual load acquisition unit 18 may pre-acquire virtual load information in association with comparison location identification data before the actual machining unit 12 operates based on the operating data, and temporarily store it in the storage unit 20.

[0037] <1-3> The drive unit 120 drives the motor 132 and movable parts 134 and 136 of the actual machining unit 12 based on the machine coordinates Xr(0) to Xr(n) (operation data) output from the numerical control device 110. As a result, the actual machining unit 12 performs machining on the workpiece W by moving the tool T and the workpiece W relative to each other.

[0038] The drive unit 120 (actual load acquisition unit 16) acquires contact information indicating whether or not the tool T and the workpiece W are in contact, as load information generated on the movable parts 134 and 136 at a certain machine coordinate Xr(j) at a certain time Tr(j). For example, the drive unit 120 (actual load acquisition unit 16) monitors the output (command or feedback information) of the motor 132, and if the output of the motor 132 exceeds a certain threshold, it determines that the tool T and the workpiece W are in contact and outputs a contact signal to the numerical control device 110.

[0039] The drive unit 120 (actual load acquisition unit 16) acquires contact signals (actual load information) in association with time Tr(j) (comparison point identification data).

[0040] <1-4> The numerical control device 110 (load information determination unit 22) compares the contact signal (actual load information) and the contact flag (virtual load information) based on the time Tr(j) and Ts(i) (comparison location identification data) and determines whether or not there is a difference between these pieces of information. For example, in Figure 4A, the numerical control device 110 (load information determination unit 22) acquires the contact signal (actual load information) between time Ts(i-1) and Ts(i) based on the time Tr(j) and Ts(i) (comparison location identification data), and since the contact flag (virtual load information) at this time is 1, it determines that there is no difference between these pieces of information.

[0041] The load information determination unit 22 performs the above determination in real time during the operation of the actual machining unit 12, based on the virtual load information obtained in advance by the simulation unit 14 and the actual load information obtained in real time by the actual machining unit 12. The load information determination unit 22 may extract and compare only the virtual load information and actual load information for a specific section in the comparison location identification data.

[0042] If there is no difference between the actual load information and the virtual load information, the numerical control device 110 (operation control unit 24) does not impose any operational restrictions.

[0043] As mentioned above, the load information determination unit 22 may be provided in the numerical control device 110, in the drive unit 120 (servo control unit, amplifier), or it may be configured by a computer different from the numerical control device 110 and the drive unit 120.

[0044] If the load information determination unit 22 is provided in the drive unit 120 (servo control unit, amplifier), the load information determination unit 22 may calculate the time Tr(j) in which a contact signal is detected in the actual machining unit 12 on the drive unit 120 side, and if this time Tr(j) and the times Ts(i-1) and Ts(i) in the simulation unit 14 when the contact flag changes from 0 to 1 satisfy the following equation, it may determine that there is no difference between the actual load information and the virtual load information. Ts(i-1)≦Tr(j)≦Ts(i)

[0045] Normally, the acquisition period for the position of the movable part in the actual machining area is shorter than the simulation period, so the error (delay time) in the time Tr(j) when the contact signal is detected in the actual machining area 12 can be ignored. However, if the error (delay time) in the actual machining area is smaller than the error in the simulation area 14, the load information determination unit 22 may determine that there is no difference between the actual load information and the virtual load information if there is a time Ts(i) in the simulation area 14 where the contact flag is 1 between time Tr(j-1) and Tr(j) in the actual machining area 12.

[0046] Furthermore, the load information determination unit 22 may determine that there is no difference between the actual load information and the virtual load information based not only on the determination by contact time as described above, but also on the determination by contact position as follows. For example, the load information determination unit 22 may further determine that there is no difference between the actual load information and the virtual load information if the machine coordinate Xr(j) where a contact signal is detected in the actual machining unit 12 and the machine coordinates Xs(i-1) and Xs(i) where the contact flag changes from 0 to 1 in the simulation unit 14 satisfy the following equation for all axes p that are operating between i-1 and i. |Xrp(j)-Xsp(i)|≦|Xsp(i)-Xsp(i-1)| This eliminates cases where the contact time (collision time) happened to coincide as a result of a series of mistakes.

[0047] (When there is a difference between the actual machined part and the simulated part) (Pattern where contact is detected only in the simulated part) <1-1> As shown in Figure 4B, for example, the numerical control device 110, as described above, creates time-series data Xs(0), Xs(1) to Xs(n) of the machine coordinates Xs(i) of the virtual movable parts 134s and 136s from the start time Ts(0) to time Ts(i) seconds later as operating data for the simulation unit 14. Also, for example, the numerical control device 110, as described above, creates time-series data Xr(0), Xr(1) to Xr(n) of the machine coordinates Xr(j) of the movable parts 134 and 136 from the start time Tr(0) to time Tr(j) seconds later as operating data for the actual machining unit 12.

[0048] <1-2> Similarly to the above, the simulation unit 14 performs a machining simulation of the virtual workpiece Ws, and the numerical control device 110 (virtual load acquisition unit 18) acquires contact flags 0 / 1 (virtual load information) in association with time Ts(i) (comparison location identification data), as shown in Figure 4B.

[0049] <1-3> As described above, the drive unit 120 and the actual machining unit 12 machine the workpiece W, and the drive unit 120 (actual load acquisition unit 16) acquires a contact signal (actual load information) in association with the time Tr(j) (comparison location identification data). For example, in Figure 4B, due to tool damage or incorrect installation, the tool T and the workpiece W do not make contact, and the drive unit 120 (actual load acquisition unit 16) does not acquire a contact signal and does not output a contact signal to the numerical control device 110.

[0050] <1-4> As described above, the numerical control device 110 (load information determination unit 22) compares the contact signal (actual load information) and the contact flag (virtual load information) based on the time Tr(j) and Ts(i) (comparison location identification data) and determines whether or not there is a difference in this information. For example, in Figure 4B, the numerical control device 110 (load information determination unit 22) does not acquire a contact signal (actual load information) between time Ts(i-1) and Ts(i), and the contact flag (virtual load information) at this time is 1, so it determines that there is a difference in this information.

[0051] If there is a discrepancy between the actual load information and the virtual load information, the numerical control device 110 (operation control unit 24) slows down and stops the machine tool 130. The numerical control device 110 (operation control unit 24) may immediately stop the motor output or perform a predetermined emergency stop operation. That is, in the actual machining section 12, the numerical control device 110 (operation control unit 24) may limit the output for operating the movable parts 134 and 136, perform a predetermined retraction operation of the movable parts 134 and 136, or immediately slow down and stop the operation of the movable parts 134 and 136.

[0052] At this time, the machine tool operator can recognize incorrect tool placement or damage by comparing the machine coordinates where contact (interference) was detected in the machining simulation with the machine coordinates where contact (interference) was detected in the actual machining, which correspond to the machine coordinates where contact (interference) was detected in the machining simulation.

[0053] (When there is a difference between the actual machined part and the simulated part) (Pattern where contact is detected only in the actual machined part) <1-1> As shown in Figure 4C, for example, the numerical control device 110, as described above, creates time-series data Xs(0), Xs(1) to Xs(n) of the machine coordinates Xs(i) of the virtual movable parts 134s and 136s from the start time Ts(0) to time Ts(i) seconds later as operating data for the simulation unit 14. Also, for example, the numerical control device 110, as described above, creates time-series data Xr(0), Xr(1) to Xr(n) of the machine coordinates Xr(j) of the movable parts 134 and 136 from the start time Tr(0) to time Tr(j) seconds later as operating data for the actual machining unit 12.

[0054] <1-2> As described above, the simulation unit 14 performs a machining simulation of the virtual workpiece Ws, and the numerical control device 110 (virtual load acquisition unit 18) acquires a contact flag 0 / 1 (virtual load information) in association with time Ts(i) (comparison location identification data), as shown in Figure 4A. For example, in Figure 4C, at a certain machine coordinate Xs(i) at a certain time Ts(i), the virtual tool Ts does not move from outside to inside the virtual workpiece Ws, and the simulation unit 14 sets the contact flag to 0.

[0055] <1-3> As described above, the drive unit 120 and the actual machining unit 12 perform machining on the workpiece W, and the drive unit 120 (actual load acquisition unit 16) acquires a contact signal (actual load information) in association with the time Tr(j) (comparison location identification data).

[0056] <1-4> As described above, the numerical control device 110 (load information determination unit 22) compares the contact signal (actual load information) and the contact flag (virtual load information) based on the time Tr(j) and Ts(i) (comparison location identification data) and determines whether or not there is a difference between these pieces of information. For example, in Figure 4B, the numerical control device 110 (load information determination unit 22) detects that a contact signal (actual load information) was acquired between time Ts(i-1) and Ts(i) even though the contact flag (virtual load information) was not set, and determines that there is a difference between these pieces of information.

[0057] Similarly, if there is a difference between the actual load information and the virtual load information, the numerical control device 110 (operation control unit 24) slows down and stops the machine tool 130.

[0058] (When there is a difference between the actual machining area and the simulation area) (Pattern where the workpiece lifts up) <1-1> As shown in Figure 4C, for example, the numerical control device 110, as described above, creates time-series data Xs(0), Xs(1) to Xs(n) of the machine coordinates Xs(i) of the virtual movable parts 134s and 136s from the start time Ts(0) to time Ts(i) seconds later as operating data for the simulation unit 14. Also, for example, the numerical control device 110, as described above, creates time-series data Xr(0), Xr(1) to Xr(n) of the machine coordinates Xr(j) of the movable parts 134 and 136 from the start time Tr(0) to time Tr(j) seconds later as operating data for the actual machining unit 12.

[0059] <1-2> As described above, the simulation unit 14 performs a machining simulation of the virtual workpiece Ws, and the numerical control device 110 (virtual load acquisition unit 18) acquires a contact flag 0 / 1 (virtual load information) in association with time Ts(i) (comparison location identification data), as shown in Figure 4A. For example, in Figure 4D, at a certain machine coordinate Xs(i) at a certain time Ts(i), the virtual tool Ts does not move from outside to inside the virtual workpiece Ws, and the simulation unit 14 sets the contact flag to 0.

[0060] <1-3> As described above, the drive unit 120 and the actual machining unit 12 machine the workpiece W, and the drive unit 120 (actual load acquisition unit 16) acquires a contact signal (actual load information) in association with the time Tr(j) (comparison location identification data). For example, in Figure 4D, if the workpiece W lifts off the table 136 due to chips or the like, or if the movable parts 134, 136 or the tool T lifts off, the tool T and the workpiece W come into contact earlier than in the simulation, and the drive unit 120 (actual load acquisition unit 16) outputs a contact signal to the numerical control device 110 earlier than in the simulation. Alternatively, if the tool T and the workpiece W come into contact later than in the simulation, the drive unit 120 (actual load acquisition unit 16) outputs a contact signal to the numerical control device 110 later than in the simulation.

[0061] <1-4> As described above, the numerical control device 110 (load information determination unit 22) compares the contact signal (actual load information) and the contact flag (virtual load information) based on the time Tr(j) and Ts(i) (comparison location identification data) and determines whether there is a difference between these pieces of information. For example, in Figure 4D, if the tool T and workpiece W come into contact earlier than in the simulation, the numerical control device 110 (load information determination unit 22) detects that a contact signal (actual load information) was acquired between time Ts(i-1) and Ts(i) even though the contact flag (virtual load information) was not set, and determines that there is a difference between these pieces of information. Alternatively, if the tool T and workpiece W come into contact later than in the simulation, the numerical control device 110 (load information determination unit 22) does not acquire a contact signal (actual load information) between time Ts(i-1) and Ts(i), and the contact flag (virtual load information) at this time is 1, so it determines that there is a difference between these pieces of information.

[0062] Similarly, if there is a difference between the actual load information and the virtual load information, the numerical control device 110 (operation control unit 24) slows down and stops the machine tool 130.

[0063] [Example 2] In Example 2, machine coordinates (position information of the movable part) are used as the data for identifying the comparison point. This makes it possible to accurately determine whether or not there is a difference between the actual load information and the virtual load information, even when there is a significant difference in time (delay) between the simulation and the actual machining due to external factors of the machine tool. Figure 5A shows the case where there is no difference between the actual load information of the movable part in the actual machining area and the virtual load information of the virtual movable part in the simulation area. Figure 5B shows the case where there is a difference between the actual load information of the movable part in the actual machining area and the virtual load information of the virtual movable part in the simulation area (a pattern in which contact is detected only in the simulation area). Figure 5C shows the case where there is a difference between the actual load information of the movable part in the actual machining area and the virtual load information of the virtual movable part in the simulation area (a pattern in which contact is detected only in the actual machining area).

[0064] (If there is no difference between the actual machining part and the simulation part) <2-1> As shown in Figure 5A, for example, the numerical control device 110 analyzes the machining program and creates time-series data Xs(0), Xs(1) to Xs(n) of the machine coordinates Xs(i) of the virtual movable parts 134s and 136s from the start time Ts(0) to time Ts(i) seconds later as operating data for the simulation unit 14, and outputs it to the simulation unit 14. Also, for example, the numerical control device 110 analyzes the machining program and creates time-series data Xr(0), Xr(1) to Xr(n) of the machine coordinates Xr(j) of the movable parts 134 and 136 from the start time Tr(0) to time Tr(j) seconds later as operating data for the actual machining unit 12, and outputs it to the drive unit 120. Here, i and j are any integers from 1 to n. n is an integer greater than or equal to 1.

[0065] In this embodiment, the numerical control device 110 is shown as an example in which it analyzes the machining program and creates time-series data (operation data) of machine coordinates. However, this embodiment is not limited to this, and a computer constituting the simulation unit 14 or another computer may analyze the machining program and create time-series data (operation data) of machine coordinates.

[0066] <2-2> The simulation unit 14 performs a machining simulation of the virtual workpiece Ws by relatively moving the virtual tool Ts and the virtual workpiece Ws based on the machine coordinates Xs(0) to Xs(n) (operation data) output from the numerical control device 110.

[0067] The simulation unit 14 calculates contact information indicating whether or not the virtual tool Ts and the virtual workpiece Ws are in contact, as virtual load information occurring at a certain machine coordinate Xs(i) at a certain time Ts(i) in the virtual movable parts 134s and 136s. For example, the simulation unit 14 sets the contact flag to 0 if the virtual tool Ts is outside the virtual workpiece Ws, and sets the contact flag to 1 if the virtual tool Ts moves from outside to inside the virtual workpiece Ws.

[0068] Furthermore, the simulation unit 14 calculates a machine coordinate Xs(i) at a certain time Ts(i) as comparison point identification data to identify the comparison point between the virtual load information and the actual load information. Specifically, the comparison point identification data is data that associates the virtual load information and the actual load information in terms of time series or machining position. More specifically, the comparison point identification data is data that establishes a one-to-one correspondence between the machine coordinate Xs(i) where the virtual tool Ts and the virtual workpiece Ws come into contact in the simulation unit 14 and the machine coordinate Xr(j) where the tool T and the workpiece W come into contact in the actual machining unit 12. In other words, the comparison point identification data is data that identifies the machine coordinate Xs(i) and the machine coordinate Xr(j) as the comparison point between the virtual load information and the actual load information. As a result, the load information determination unit 22 can appropriately compare the virtual load information of machine coordinate Xs(i) and the actual load information of machine coordinate Xr(j) based on the comparison point identification data. As mentioned above, the simulation unit 14 may be provided in the numerical control device 110, or it may be configured by a computer different from the numerical control device 110.

[0069] As shown in Figure 5A, the numerical control device 110 (virtual load acquisition unit 18) acquires contact flags 0 / 1 (virtual load information) in association with machine coordinates Xs(i) (comparison location identification data).

[0070] The simulation unit 14 performs the above-mentioned machining simulation before the actual machining unit 12 operates based on the operating data, and pre-calculates virtual load information and comparison location data. Alternatively, the virtual load acquisition unit 18 may pre-acquire virtual load information in association with comparison location identification data before the actual machining unit 12 operates based on the operating data, and temporarily store it in the storage unit 20.

[0071] <2-3> The drive unit 120 drives the motor 132 and movable parts 134 and 136 of the actual machining unit 12 based on the machine coordinates Xr(0) to Xr(n) (operation data) output from the numerical control device 110. As a result, the actual machining unit 12 performs machining on the workpiece W by moving the tool T and the workpiece W relative to each other.

[0072] The drive unit 120 (actual load acquisition unit 16) acquires contact information indicating whether or not the tool T and the workpiece W are in contact, as load information generated on the movable parts 134 and 136 at a certain machine coordinate Xr(j) at a certain time Tr(j). For example, the drive unit 120 (actual load acquisition unit 16) monitors the output (command or feedback information) of the motor 132, and if the output of the motor 132 exceeds a certain threshold, it determines that the tool T and the workpiece W are in contact and outputs a contact signal to the numerical control device 110.

[0073] The drive unit 120 (actual load acquisition unit 16) acquires contact signals (actual load information) in association with machine coordinates Xr(j) (comparison location identification data).

[0074] <2-4> The numerical control device 110 (load information determination unit 22) compares the contact signal (actual load information) and the contact flag (virtual load information) based on the machine coordinates Xr(j) and Xs(i) (comparison location identification data) and determines whether or not there is a difference between this information. For example, in Figure 5A, the numerical control device 110 (load information determination unit 22) determines that there is no difference between the actual load information and the virtual load information because the machine coordinate Xr(j) (comparison location identification data) where the contact signal (actual load information) is detected in the actual machining unit 12 and the machine coordinates Xs(i-1) and Xs(i) (comparison location identification data) where the contact flag (virtual load information) changes from 0 to 1 in the simulation unit 14 satisfy the following inequality for all axes p that operate between i-1 and i. |Xrp(j)-Xsp(i)|≦|Xsp(i)-Xsp(i-1)|

[0075] Furthermore, if there are multiple machine coordinates Xr(j) (comparison location identification data) where a contact signal (actual load information) is detected in the actual machining unit 12, and multiple machine coordinates Xs(i) (comparison location identification data) where the contact flag (virtual load information) changes from 0 to 1 in the simulation unit 14, the above determination may be performed in the order in which contact occurred.

[0076] The load information determination unit 22 performs the above determination in real time during the operation of the actual machining unit 12, based on the virtual load information obtained in advance by the simulation unit 14 and the actual load information obtained in real time by the actual machining unit 12. The load information determination unit 22 may extract and compare only the virtual load information and actual load information for a specific section in the comparison location identification data.

[0077] If there is no difference between the actual load information and the virtual load information, the numerical control device 110 (operation control unit 24) does not impose any operational restrictions.

[0078] As mentioned above, the load information determination unit 22 may be provided in the numerical control device 110, in the drive unit 120 (servo control unit, amplifier), or it may be configured by a computer different from the numerical control device 110 and the drive unit 120.

[0079] (When there is a difference between the actual machined part and the simulated part) (Pattern where contact is detected only in the simulated part) <2-1> As shown in Figure 5B, for example, the numerical control device 110, as described above, creates time-series data Xs(0), Xs(1) to Xs(n) of the machine coordinates Xs(i) of the virtual movable parts 134s and 136s from the start time Ts(0) to time Ts(i) seconds later as operating data for the simulation unit 14. Also, for example, the numerical control device 110, as described above, creates time-series data Xr(0), Xr(1) to Xr(n) of the machine coordinates Xr(j) of the movable parts 134 and 136 from the start time Tr(0) to time Tr(j) seconds later as operating data for the actual machining unit 12.

[0080] <2-2> Similarly to the above, the simulation unit 14 performs a machining simulation of the virtual workpiece Ws, and the numerical control device 110 (virtual load acquisition unit 18) acquires contact flags 0 / 1 (virtual load information) in association with machine coordinates Xs(i) (comparison location identification data), as shown in Figure 5B.

[0081] <2-3> As described above, the drive unit 120 and the actual machining unit 12 machine the workpiece W, and the drive unit 120 (actual load acquisition unit 16) acquires a contact signal (actual load information) in association with machine coordinates Xr(j) (comparison location identification data). For example, in Figure 5B, due to tool damage or incorrect installation, the tool T and the workpiece W do not make contact, and the drive unit 120 (actual load acquisition unit 16) does not acquire a contact signal and does not output a contact signal to the numerical control device 110.

[0082] Furthermore, if contact is detected at another location after a certain amount of processing has progressed, the drive unit 120 (actual load acquisition unit 16) may output the contact signal (actual load information) and machine coordinates Xr(k) (comparison location identification data) to the numerical control device 110.

[0083] <2-4> As described above, the numerical control device 110 (load information determination unit 22) compares the contact signal (actual load information) and the contact flag (virtual load information) based on the machine coordinates Xr(j) and Xs(i) (comparison location identification data) and determines whether or not there is a difference in this information. For example, in Figure 5B, the numerical control device 110 (load information determination unit 22) determines that there is a difference in this information because the actual machining unit 12 does not acquire a contact signal (actual load information), while the simulation unit 14 has a contact flag (virtual load information) of 1. Alternatively, the numerical control device 110 (load information determination unit 22) determines that there is a difference between the actual load information and the virtual load information because the machine coordinate Xr(k) (comparison location identification data) where a contact signal (actual load information) is detected in the actual machining unit 12 and the machine coordinates Xs(i-1), Xs(i) (comparison location identification data) where the contact flag (virtual load information) changes from 0 to 1 in the simulation unit 14 do not satisfy the following inequality for all axes p that operate between i-1 and i. |Xrp(k)-Xsp(i)|≦|Xsp(i)-Xsp(i-1)|

[0084] If there is a discrepancy between the actual load information and the virtual load information, the numerical control device 110 (operation control unit 24) slows down and stops the machine tool 130. The numerical control device 110 (operation control unit 24) may immediately stop the motor output or perform a predetermined emergency stop operation. That is, in the actual machining section 12, the numerical control device 110 (operation control unit 24) may limit the output for operating the movable parts 134 and 136, perform a predetermined retraction operation of the movable parts 134 and 136, or immediately slow down and stop the operation of the movable parts 134 and 136.

[0085] At this time, the machine tool operator can recognize incorrect tool placement or damage by comparing the machine coordinates where contact (interference) was detected in the machining simulation with the machine coordinates where contact (interference) was detected in the actual machining, which correspond to the machine coordinates where contact (interference) was detected in the machining simulation.

[0086] (When there is a difference between the actual machined part and the simulated part) (Pattern where contact is detected only in the actual machined part) <2-1> As shown in Figure 5C, for example, the numerical control device 110, as described above, creates time-series data Xs(0), Xs(1) to Xs(n) of the machine coordinates Xs(i) of the virtual movable parts 134s and 136s from the start time Ts(0) to time Ts(i) seconds later as operating data for the simulation unit 14. Also, for example, the numerical control device 110, as described above, creates time-series data Xr(0), Xr(1) to Xr(n) of the machine coordinates Xr(j) of the movable parts 134 and 136 from the start time Tr(0) to time Tr(j) seconds later as operating data for the actual machining unit 12.

[0087] <2-2> As described above, the simulation unit 14 performs a machining simulation of the virtual workpiece Ws, and the numerical control device 110 (virtual load acquisition unit 18) acquires a contact flag 0 / 1 (virtual load information) in association with the machine coordinate Xs(i) (comparison location identification data), as shown in Figure 5B. In Figure 5C, at a certain machine coordinate Xs(i) at a certain time Ts(i), the virtual tool Ts does not move from outside to inside the virtual workpiece Ws, and the simulation unit 14 sets the contact flag to 0.

[0088] Furthermore, if contact is detected at a different location after a certain amount of processing has progressed, the numerical control device 110 (virtual load acquisition unit 18) may acquire a contact flag 1 (virtual load information) in association with the machine coordinates Xs(k) (comparison location identification data) where the contact was detected.

[0089] <2-3> As described above, the drive unit 120 and the actual machining unit 12 perform machining on the workpiece W, and the drive unit 120 (actual load acquisition unit 16) acquires a contact signal (actual load information) in association with machine coordinates Xr(j) (comparison location identification data).

[0090] <2-4> Similarly to the above, the numerical control device 110 (load information determination unit 22) compares the contact signal (actual load information) and the contact flag (virtual load information) based on the machine coordinates Xr(j) and Xs(i) (comparison location identification data) and determines whether or not there is a difference in this information. For example, in Figure 5C, the numerical control device 110 (load information determination unit 22) determines that there is a difference in this information because the contact flag (virtual load information) is 0 in the machine coordinate Xs(i) (comparison location identification data) in the simulation unit 14, which corresponds to the machine coordinate Xr(j) (comparison location identification data) in the actual machining unit 12 where the contact signal (actual load information) was detected. Alternatively, the numerical control device 110 (load information determination unit 22) determines that there is a difference between the actual load information and the virtual load information because the machine coordinate Xr(j) (comparison location identification data) where a contact signal (actual load information) is detected in the actual machining unit 12 and the machine coordinates Xs(k-1), Xs(k) (comparison location identification data) where the contact flag (virtual load information) changes from 0 to 1 in the simulation unit 14 do not satisfy the following inequality for all axes p that operate between i-1 and i. |Xrp(j)-Xsp(k)|≦|Xsp(k)-Xsp(k-1)|

[0091] Similarly, if there is a difference between the actual load information and the virtual load information, the numerical control device 110 (operation control unit 24) slows down and stops the machine tool 130.

[0092] [Example 3] In Example 3, operation data is used as comparison point identification data. By including machine coordinates in the operation data, it becomes easier to identify problem areas in the machining data. Figure 6A shows the case where there is no difference between the actual load information of the movable part in the actual machining area and the virtual load information of the virtual movable part in the simulation area. Figure 6B shows the case where there is a difference between the actual load information of the movable part in the actual machining area and the virtual load information of the virtual movable part in the simulation area (a pattern in which contact is detected only in the simulation area). Figure 6C shows the case where there is a difference between the actual load information of the movable part in the actual machining area and the virtual load information of the virtual movable part in the simulation area (a pattern in which contact is detected only in the actual machining area).

[0093] (If there is no difference between the actual machining part and the simulation part) <3-1> As shown in Figure 6A, for example, the simulation unit 14 analyzes the machining program and creates time-series data Xs(0), Xs(1) to Xs(n) of the machine coordinates Xs(i) of the virtual movable parts 134s and 136s from the start time Ts(0) to time Ts(i) seconds later as operating data for the simulation unit 14. On the other hand, for example, the numerical control device 110 analyzes the machining program and creates time-series data Xr(0), Xr(1) to Xr(n) of the machine coordinates Xr(j) of the movable parts 134 and 136 from the start time Tr(0) to time Tr(j) seconds later as operating data for the actual machining unit 12, and outputs it to the drive unit 120. Here, i and j are any integers from 1 to n. n is an integer greater than or equal to 1.

[0094] <3-2> The simulation unit 14 performs a machining simulation of the virtual workpiece Ws by relatively moving the virtual tool Ts and the virtual workpiece Ws based on the machine coordinates Xs(0) to Xs(n) (operation data).

[0095] The simulation unit 14 calculates contact information indicating whether or not the virtual tool Ts and the virtual workpiece Ws are in contact, as virtual load information occurring at a certain machine coordinate Xs(i) at a certain time Ts(i) in the virtual movable parts 134s and 136s. The simulation unit 14 also calculates a certain machine coordinate Xs(i) at a certain time Ts(i) as comparison point identification data to identify the point where the virtual load information and the actual load information are compared. For example, if the virtual tool Ts enters the virtual workpiece Ws from outside to inside between machine coordinates Xs(j-1) and Xs(j), the simulation unit 14 appends the coordinates of machine coordinate Xs(j) in the format ",Ln X_Y_Z_" in association with the command block in the operation data (virtual load information and comparison point identification data). Here, n is an integer of 1 or more, and if contact occurs multiple times within one block, n is incremented to describe multiple contacts.

[0096] Furthermore, if the operating data is a small line segment, the coordinates of the machine coordinate Xs(j) may be added in units of one block instead of in units of command blocks (virtual load information and comparison point identification data). Although the example was given for a machine with three feed axes, this embodiment is also applicable to machines with four or more feed axes.

[0097] The comparison point identification data is data that associates virtual load information with actual load information in terms of time series or machining location. More specifically, the comparison point identification data is data that establishes a one-to-one correspondence between the machine coordinate Xs(i) where the virtual tool Ts and virtual workpiece Ws contact in the simulation unit 14 and the machine coordinate Xr(j) where the tool T and workpiece W contact in the actual machining unit 12. In other words, the comparison point identification data identifies the machine coordinate Xs(i) and machine coordinate Xr(j) as comparison points between virtual load information and actual load information. As a result, the load information determination unit 22 can appropriately compare the virtual load information at machine coordinate Xs(i) and the actual load information at machine coordinate Xr(j) based on the comparison point identification data.

[0098] As shown in Figure 6A, the numerical control device 110 (virtual load acquisition unit 18) acquires ",Ln X_Y_Z_" (virtual load information and comparison point identification data) that has been added to the operation data.

[0099] The simulation unit 14 performs the above-mentioned machining simulation before the actual machining unit 12 operates based on the operating data, and pre-calculates virtual load information and comparison location data. Alternatively, the virtual load acquisition unit 18 may pre-acquire virtual load information in association with comparison location identification data before the actual machining unit 12 operates based on the operating data, and temporarily store it in the storage unit 20.

[0100] <3-3> The drive unit 120 drives the motor 132 and movable parts 134 and 136 of the actual machining unit 12 based on the machine coordinates Xr(0) to Xr(n) (operation data) output from the numerical control device 110. As a result, the actual machining unit 12 performs machining on the workpiece W by moving the tool T and the workpiece W relative to each other.

[0101] The drive unit 120 (actual load acquisition unit 16) acquires contact information indicating whether or not the tool T and the workpiece W are in contact, as load information generated on the movable parts 134 and 136 at a certain machine coordinate Xr(j) at a certain time Tr(j). For example, the drive unit 120 (actual load acquisition unit 16) monitors the output (command or feedback information) of the motor 132, and if the output of the motor 132 exceeds a certain threshold, it determines that the tool T and the workpiece W are in contact and outputs a contact signal to the numerical control device 110.

[0102] The drive unit 120 (actual load acquisition unit 16) acquires contact signals (actual load information) in association with machine coordinates Xr(j) (comparison location identification data).

[0103] <3-4> The numerical control device 110 (load information determination unit 22) compares the contact signal (actual load information) with the presence or absence of contact (virtual load information) based on the machine coordinates Xr(j) and Xs(i) (comparison location identification data) and determines whether or not there is a difference between this information. For example, in Figure 6A, the numerical control device 110 (load information determination unit 22) determines that there is no difference between the actual load information and the virtual load information because the machine coordinate Xr(j) (comparison location identification data) where the contact signal (actual load information) was detected in the actual machining unit 12 and the machine coordinate Xs(i) (comparison location identification data) indicated by ",Ln X_Y_Z_" added to the operation data in the simulation unit 14 satisfy the following inequality for all axes p that operate between i-1 and i. |Xrp(j)-Xsp(i)|≦|Xsp(i)-Xsp(i-1)| If the operating data contains multiple ",Ln X_Y_Z_" (virtual load information and comparison point identification data), the above determination should be performed in order of increasing value of n.

[0104] The load information determination unit 22 performs the above determination in real time during the operation of the actual machining unit 12, based on the virtual load information obtained in advance by the simulation unit 14 and the actual load information obtained in real time by the actual machining unit 12. The load information determination unit 22 may extract and compare only the virtual load information and actual load information for a specific section in the comparison location identification data.

[0105] If there is no difference between the actual load information and the virtual load information, the numerical control device 110 (operation control unit 24) does not impose any operational restrictions.

[0106] Normally, the acquisition period for the position of the movable part in the actual machining area is shorter than the simulation period, so the error in the machine coordinate Xr(j) where a contact signal is detected in the actual machining area 12 can be ignored. However, if the error in the simulation area 14 is smaller than the error in the actual machining area, the load information determination unit 22 may determine that there is no difference between the actual load information and the virtual load information if there is a machine coordinate Xs(i) that is in contact with the simulation area 14 between machine coordinate Xr(j-1) and Xr(j) in the actual machining area 12. In other words, it may be confirmed that the following equality holds for all axes p that operate between i-1 and i. |Xrp(j)-Xsp(i)|≦|Xrp(j)-Xrp(j-1)|

[0107] (When there is a difference between the actual machined part and the simulated part) (Pattern where contact is detected only in the simulated part) <3-1> As shown in Figure 6B, for example, the simulation unit 14, as described above, creates time-series data Xs(0), Xs(1) to Xs(n) of the machine coordinates Xs(i) of the virtual movable parts 134s and 136s from the start time Ts(0) to time Ts(i) seconds later as operating data for the simulation unit 14. On the other hand, for example, the numerical control device 110, as described above, creates time-series data Xr(0), Xr(1) to Xr(n) of the machine coordinates Xr(j) of the movable parts 134 and 136 from the start time Tr(0) to time Tr(j) seconds later as operating data for the actual machining unit 12.

[0108] <3-2> Similarly to the above, the simulation unit 14 performs a machining simulation of the virtual workpiece Ws, and the numerical control device 110 (virtual load acquisition unit 18) acquires ",Ln X_Y_Z_" (virtual load information and comparison point identification data) appended to the operation data, as shown in Figure 6B.

[0109] <3-3> As described above, the drive unit 120 and the actual machining unit 12 machine the workpiece W, and the drive unit 120 (actual load acquisition unit 16) acquires a contact signal (actual load information) in association with machine coordinates Xr(j) (comparison location identification data). For example, in Figure 6B, due to tool damage or incorrect installation, the tool T and the workpiece W do not make contact, and the drive unit 120 (actual load acquisition unit 16) does not acquire a contact signal and does not output a contact signal to the numerical control device 110.

[0110] <3-4> Similarly, the numerical control device 110 (load information determination unit 22) compares the contact signal (actual load information) with the presence or absence of contact (virtual load information) based on the machine coordinates Xr(j) and Xs(i) (comparison location identification data) and determines whether or not there is a difference in this information. For example, in Figure 6B, the numerical control device 110 (load information determination unit 22) determines that there is a difference in this information because, in the actual machining unit 12, even though the drive unit 120 (actual load acquisition unit 16) has not acquired a contact signal, the block (comparison location identification data) corresponding to the block containing ",Ln X_Y_Z_" (virtual load information and comparison location identification data) in the operation data of the simulation unit 14 has passed.

[0111] If there is a discrepancy between the actual load information and the virtual load information, the numerical control device 110 (operation control unit 24) slows down and stops the machine tool 130. The numerical control device 110 (operation control unit 24) may immediately stop the motor output or perform a predetermined emergency stop operation. That is, in the actual machining section 12, the numerical control device 110 (operation control unit 24) may limit the output for operating the movable parts 134 and 136, perform a predetermined retraction operation of the movable parts 134 and 136, or immediately slow down and stop the operation of the movable parts 134 and 136.

[0112] Furthermore, the display unit 28 may display the machine coordinates Xs(i) of the operating data in which contact (interference) between the virtual tool Ts and the virtual workpiece Ws is detected in the simulation unit 14 in a different color from other operating data, or it may flash. This allows the machine tool operator to easily recognize the machine coordinates Xs(i) of the operating data in which contact (interference) between the virtual tool Ts and the virtual workpiece Ws is detected in the simulation unit 14.

[0113] (When there is a difference between the actual machined part and the simulated part) (Pattern where contact is detected only in the actual machined part) <3-1> As shown in Figure 6C, for example, the simulation unit 14, as described above, creates time-series data Xs(0), Xs(1) to Xs(n) of the machine coordinates Xs(i) of the virtual movable parts 134s and 136s from the start time Ts(0) to time Ts(i) seconds later as operating data for the simulation unit 14. On the other hand, for example, the numerical control device 110, as described above, creates time-series data Xr(0), Xr(1) to Xr(n) of the machine coordinates Xr(j) of the movable parts 134 and 136 from the start time Tr(0) to time Tr(j) seconds later as operating data for the actual machining unit 12.

[0114] <3-2> As described above, the simulation unit 14 performs a machining simulation of the virtual workpiece Ws, and the numerical control device 110 (virtual load acquisition unit 18) acquires ",Ln X_Y_Z_" (virtual load information and comparison location identification data) appended to the operation data, as shown in Figure 6C. For example, in Figure 6C, the virtual tool Ts does not enter the virtual workpiece Ws from the outside, and there is no description of ",Ln X_Y_Z_" (virtual load information and comparison location identification data) in the operation data, so the numerical control device 110 (virtual load acquisition unit 18) does not acquire ",Ln X_Y_Z_" (virtual load information and comparison location identification data) appended to the operation data.

[0115] <3-3> As described above, the drive unit 120 and the actual machining unit 12 perform machining on the workpiece W, and the drive unit 120 (actual load acquisition unit 16) acquires a contact signal (actual load information) in association with machine coordinates Xr(j) (comparison location identification data).

[0116] <3-4> Similarly, the numerical control device 110 (load information determination unit 22) compares the contact signal (actual load information) with the presence or absence of contact (virtual load information) based on the machine coordinates Xr(j) and Xs(i) (comparison location identification data) and determines whether or not there is a difference in this information. For example, in Figure 6C, the numerical control device 110 (load information determination unit 22) determines that there is a difference in this information because the block of operation data in the simulation unit 14 corresponding to the machine coordinate Xr(j) (comparison location identification data) where the contact signal (actual load information) was detected in the actual machining unit 12 does not contain ",Ln X_Y_Z_" (virtual load information and comparison location identification data).

[0117] Similarly, if there is a difference between the actual load information and the virtual load information, the numerical control device 110 (operation control unit 24) slows down and stops the machine tool 130.

[0118] Furthermore, as described above, the display unit 28 may display the machine coordinate Xr(j) where contact (interference) between the tool T and the workpiece W is detected in the actual machining unit 12 in a different color from other operating data, or it may flash. This allows the machine tool operator to easily recognize the machine coordinate Xr(j) where contact (interference) between the tool T and the workpiece W is detected in the actual machining unit 12.

[0119] [Example 4] In Example 4, the magnitude of the load (energy) generated in the movable part when machining the workpiece is used as the actual load information, and the magnitude of the load (energy) generated in the virtual movable part when machining the virtual workpiece is used as the virtual load information. By obtaining the magnitude of the load (energy) instead of whether or not there is contact, it becomes possible to more accurately determine contact between the tool and the workpiece, for example, when gradually cutting.

[0120] <4-1> As shown in Figure 7, for example, the numerical control device 110 analyzes the machining program and creates time-series data Xs(0), Xs(1) to Xs(n) of the machine coordinates Xs(i) of the virtual movable parts 134s and 136s from the start time Ts(0) to time Ts(i) seconds later as operating data for the simulation unit 14, and outputs it to the simulation unit 14. Also, for example, the numerical control device 110 analyzes the machining program and creates time-series data Xr(0), Xr(1) to Xr(n) of the machine coordinates Xr(j) of the movable parts 134 and 136 from the start time Tr(0) to time Tr(j) seconds later as operating data for the actual machining unit 12, and outputs it to the drive unit 120. Here, i and j are any integers from 1 to n. n is an integer greater than or equal to 1.

[0121] In this embodiment, the numerical control device 110 is shown as an example in which it analyzes the machining program and creates time-series data (operation data) of machine coordinates. However, this embodiment is not limited to this, and a computer constituting the simulation unit 14 or another computer may analyze the machining program and create time-series data (operation data) of machine coordinates.

[0122] <4-2> The simulation unit 14 performs a machining simulation of the virtual workpiece Ws by relatively moving the virtual tool Ts and the virtual workpiece Ws based on the machine coordinates Xs(0) to Xs(n) (operation data) output from the numerical control device 110.

[0123] The simulation unit 14 calculates the total amount of virtual load Ws(i) [J / s] (energy Ws × t) as virtual load information generated in the virtual movable parts 134s and 136s at a certain machine coordinate Xs(i) at a certain time Ts(i).

[0124] The following is an example of calculating the total virtual load Ws(i) [J / s] (energy Ws × t). Consider the case where the virtual movable parts 134s and 136s move from machine coordinate Xs(i-1) at time Ts(i-1) to machine coordinate Xs(i) at time Ts(i). Assuming that the energy required to remove the virtual workpiece Ws is proportional to the volume removed (proportionality constant k), and that the total coefficient of friction when operating a movable part of mass m is always constant (n), the total virtual load per unit time Ws(i) from time T(i-1) to T(i) can be expressed by the following equation.

number

[0125] In the numerator of the right-hand side of the above equation, the first term is the energy required to remove the virtual workpiece Ws, the second term is the change in kinetic energy, the third term is the change in potential energy, and the fourth term is the energy consumed by the motion of the virtual movable part.

[0126] Vs(i) is the volume of the removal region, which is the overlapping region between the area traversed by the virtual tool Ts and the area of ​​the virtual workpiece Ws between Ts(i-1) and Ts(i). Vs(i) is the velocity of i and can be expressed by the following equation.

number

[0127] Furthermore, the simulation unit 14 calculates a machine coordinate Xs(i) at a certain time Ts(i) as comparison point identification data to identify the comparison point between the virtual load information and the actual load information. Specifically, the comparison point identification data is data that associates the virtual load information and the actual load information in terms of time series or machining position. More specifically, the comparison point identification data is data that establishes a one-to-one correspondence between the time Ts(i) at which the virtual tool Ts and the virtual workpiece Ws come into contact in the simulation unit 14 and the time Tr(j) at which the tool T and the workpiece W come into contact in the actual machining unit 12. In other words, the comparison point identification data is data that identifies time Ts(i) and time Tr(j) as the comparison point between the virtual load information and the actual load information. As a result, the load information determination unit 22 can appropriately compare the virtual load information at time Ts(i) and the actual load information at time Tr(j) based on the comparison point identification data. As mentioned above, the simulation unit 14 may be provided in the numerical control device 110, or it may be configured by a computer different from the numerical control device 110.

[0128] As shown in Figure 7, the numerical control device 110 (virtual load acquisition unit 18) acquires the load Ws(i) [J / s] (energy Ws × t) (virtual load information) in association with the time Ts(i) (comparison point identification data).

[0129] The simulation unit 14 performs the above-mentioned machining simulation before the actual machining unit 12 operates based on the operating data, and pre-calculates virtual load information and comparison location data. Alternatively, the virtual load acquisition unit 18 may pre-acquire virtual load information in association with comparison location identification data before the actual machining unit 12 operates based on the operating data, and temporarily store it in the storage unit 20.

[0130] <4-3> The drive unit 120 drives the motor 132 and movable parts 134 and 136 of the actual machining unit 12 based on the machine coordinates Xr(0) to Xr(n) (operation data) output from the numerical control device 110. As a result, the actual machining unit 12 performs machining on the workpiece W by moving the tool T and the workpiece W relative to each other.

[0131] The drive unit 120 (actual load acquisition unit 16) calculates the total load of the motor, Wr(j) [J / s] (energy Wr × t), as actual load information generated on the movable parts 134 and 136 at a certain mechanical coordinate Xr(j) at a certain time Tr(j). The calculation of the load Wr(j) [J / s] (energy Wr × t) can be the same as the example of calculating the load Ws(i) [J / s] (energy Ws × t) described above.

[0132] If the machine tool is an electrical discharge machining (EDM) machine, you just need to add the power flowing to the tool to the total load on the motor.

[0133] As shown in Figure 7, the drive unit 120 (actual load acquisition unit 16) acquires the load Wr(j) [J / s] (energy Wr × t) (actual load information) in association with the time Tr(j) (comparison point identification data).

[0134] <4-4> The numerical control device 110 (load information determination unit 22) compares the load Wr(j) [J / s] (energy Wr × t) (actual load information) and the load Ws(i) [J / s] (energy Ws × t) (virtual load information) based on the time Tr(j) and Ts(i) (comparison location identification data), and determines whether or not there is a difference between these pieces of information. For example, in Figure 7, the numerical control device 110 (load information determination unit 22) finds the minimum j(jmin) and maximum j(jmax) that satisfy the following formula at time Ts(i). Ts(i-1)≦Tr(j) <Ts(i)

[0135] The numerical control device 110 (load information determination unit 22) determines whether the following equation is satisfied in i. If the following equation is satisfied, the numerical control device 110 (load information determination unit 22) determines that there is no difference between the actual load information and the virtual load information. [Number] Here, jmin and jmax are the minimum and maximum j that satisfy Ts(i - 1) ≤ Tr(j) < Ts(i), ΔTs is the simulation period, ΔTr is the period for obtaining the motor output in the actual processing part, and ΔW[J] is a certain threshold indicating the load of the motor. Note that the above formula is based on the premise that ΔTs > ΔTr.

[0136] Note that when the motor output is smaller than a certain threshold, it may be considered that the workpiece and the tool are not in contact in the actual processing part, and the comparison may not be performed.

[0137] The load information determination unit 22 performs the above determination in real time during the operation of the actual processing part 12 based on the virtual load information obtained in advance by the simulation part 14 and the real load information obtained in real time by the actual processing part 12. The load information determination unit 22 may extract and compare only the virtual load information and the real load information in a certain specific section in the comparison location specific data.

[0138] When there is no difference between the real load information and the virtual load information, the numerical control device 110 (operation control unit 24) does not perform operation restriction.

[0139] Note that as described above, the load information determination unit 22 may be provided in the numerical control device 110, may be provided in the drive unit 120 (servo control unit, amplifier), or may be configured by a computer different from the numerical control device 110 and the drive unit 120.

[0140] [Example 5] In the above-described Examples 1 to 4, a form of performing operation restriction of actual processing was exemplified assuming that there is a defect in actual processing. In Example 5, when there is a defect in the setting of the machining simulation, the setting of the machining simulation is changed (corrected). Thus, by reflecting the difference between the real load information and the virtual load information in the machining simulation, the simulation accuracy can be improved.

[0141] <5-1> As shown in Figure 8, for example, the numerical control device 110 analyzes the machining program and creates time-series data Xs(0), Xs(1) to Xs(n) of the machine coordinates Xs(i) of the virtual movable parts 134s and 136s from the start time Ts(0) to time Ts(i) seconds later as operating data for the simulation unit 14, and outputs it to the simulation unit 14. Also, for example, the numerical control device 110 analyzes the machining program and creates time-series data Xr(0), Xr(1) to Xr(n) of the machine coordinates Xr(j) of the movable parts 134 and 136 from the start time Tr(0) to time Tr(j) seconds later as operating data for the actual machining unit 12, and outputs it to the drive unit 120. Here, i and j are any integers from 1 to n. n is an integer greater than or equal to 1.

[0142] In this embodiment, the numerical control device 110 is shown as an example in which it analyzes the machining program and creates time-series data (operation data) of machine coordinates. However, this embodiment is not limited to this, and a computer constituting the simulation unit 14 or another computer may analyze the machining program and create time-series data (operation data) of machine coordinates.

[0143] <5-2> The drive unit 120 drives the motor 132 and movable parts 134 and 136 of the actual machining unit 12 based on the machine coordinates Xr(0) to Xr(n) (operation data) output from the numerical control device 110. As a result, the actual machining unit 12 performs machining on the workpiece W by moving the tool T and the workpiece W relative to each other.

[0144] The drive unit 120 (actual load acquisition unit 16) acquires contact information indicating whether or not the tool T and the workpiece W are in contact, as load information generated on the movable parts 134 and 136 at a certain machine coordinate Xr(j) at a certain time Tr(j). For example, the drive unit 120 (actual load acquisition unit 16) monitors the output (command or feedback information) of the motor 132, sets the contact signal to 0 if the output of the motor 132 does not exceed a certain threshold, and determines that the tool T and the workpiece W are in contact and sets the contact signal to 1 if the output of the motor 132 exceeds a certain threshold.

[0145] The drive unit 120 (actual load acquisition unit 16) acquires contact signals (actual load information) in association with machine coordinates Xr(j) (comparison location identification data).

[0146] The comparison point identification data is data that associates virtual load information with actual load information in terms of time series or machining location. More specifically, the comparison point identification data is data that establishes a one-to-one correspondence between the machine coordinate Xs(i) where the virtual tool Ts and virtual workpiece Ws contact in the simulation unit 14 and the machine coordinate Xr(j) where the tool T and workpiece W contact in the actual machining unit 12. In other words, the comparison point identification data identifies the machine coordinate Xs(i) and machine coordinate Xr(j) as comparison points between virtual load information and actual load information. As a result, the load information determination unit 22 can appropriately compare the virtual load information at machine coordinate Xs(i) and the actual load information at machine coordinate Xr(j) based on the comparison point identification data.

[0147] <5-3> The simulation unit 14 performs a machining simulation of the virtual workpiece Ws by relatively moving the virtual tool Ts and the virtual workpiece Ws based on the machine coordinates Xs(0) to Xs(n) (operation data) output from the numerical control device 110.

[0148] The simulation unit 14 calculates contact information indicating whether or not the virtual tool Ts and the virtual workpiece Ws are in contact, as virtual load information occurring at a certain machine coordinate Xs(i) at a certain time Ts(i) in the virtual movable parts 134s and 136s. For example, the simulation unit 14 sets the contact flag to 0 if the virtual tool Ts is outside the virtual workpiece Ws, and sets the contact flag to 1 if the virtual tool Ts moves from outside to inside the virtual workpiece Ws.

[0149] Furthermore, the simulation unit 14 calculates a machine coordinate Xs(i) at a certain time Ts(i) as comparison point identification data to identify the point where the virtual load information and the actual load information are compared. As mentioned above, the simulation unit 14 may be provided in the numerical control device 110, or it may be configured by a computer different from the numerical control device 110.

[0150] The numerical control device 110 (virtual load acquisition unit 18) acquires contact flags 0 / 1 (virtual load information) in association with machine coordinates Xs(i) (comparison location identification data).

[0151] <5-4> The simulation unit 14 (load information determination unit 22) compares the contact signal (actual load information) and the contact flag (virtual load information) based on the machine coordinates Xr(j) and Xs(i) (comparison location identification data) and determines whether or not there is a difference between this information. For example, in Figure 8, the numerical control device 110 (load information determination unit 22) determines that there is a difference between the actual load information and the virtual load information if the machine coordinate Xr(j) (comparison location identification data) where the contact signal (actual load information) is detected in the actual machining unit 12 is different from the machine coordinate Xs(i) (comparison location identification data) where the contact flag (virtual load information) changes from 0 to 1 in the simulation unit 14, based on the machine coordinates Xr(j) and Xs(i) (comparison location identification data).

[0152] The load information determination unit 22 may extract and compare only the virtual load information and actual load information for a specific section in the comparison location identification data.

[0153] If there is a discrepancy between the actual load information and the virtual load information, the simulation unit 14 (correction unit 26) changes (corrects) the preconditions of the simulation unit 14. The preconditions of the simulation unit 14 include, for example, items described in the operation data, and include preconditions related to virtual tools, virtual workpieces, and virtual moving parts.

[0154] For example, in Figure 8, the simulation unit 14 (correction unit 26) calculates the difference between the machine coordinates in the simulation unit 14 corresponding to the machine coordinate Xr(j) where a contact signal (actual load information) was detected in the actual machining unit 12, and the machine coordinates of the boundary of the virtual workpiece Ws. This difference is then reflected in the preconditions of the simulation unit so that it is changed as the setting value for the radius R of the virtual tool Ts.

[0155] Alternatively, the simulation unit 14 (correction unit 26) may calculate the difference between the machine coordinate Xr(j) where a contact signal (actual load information) is detected in the actual machining unit 12 and the machine coordinate Xs(i) where a contact flag (virtual load information) is detected in the simulation unit 14, and use this difference as the correction amount for the virtual tool Ts. This difference may then be reflected in the preconditions of the simulation unit so as to change (correct) the setting value of the virtual tool Ts by this correction amount.

[0156] Alternatively, the simulation unit 14 (correction unit 26) may identify a process with discrepancies in this information based on the machine coordinate Xr(j) (comparison location identification data) where a contact signal (actual load information) is detected in the actual machining unit 12, and the machine coordinate Xs(i) (comparison location identification data) where the contact flag (virtual load information) changes from 0 to 1 in the simulation unit 14, and change (correct) the preconditions for the machining simulation.

[0157] As described above, the machining load determination system 10 of this embodiment acquires virtual load information from machining simulations in association with comparison point identification data, and acquires actual load information from actual machining in association with comparison point identification data. Therefore, these load information can be appropriately compared based on the comparison point identification data without performing machining simulations in real time for actual machining. As a result, machining simulations can be performed in advance before actual machining, eliminating the need to shorten the processing time of the machining simulations to match the operating time of the actual machining, and thus the accuracy of the machining simulations is not limited, i.e., the accuracy of the machining simulations can be improved. As a result, the accuracy of detecting differences between machining simulations and actual machining can be improved, and malfunctions that could not be prevented in the past can be correctly detected.

[0158] In the technology disclosed in Patent Document 1, if the same operation is repeated with the same operating data, it is necessary to continuously perform the same simulation, which requires resources. In this respect, in this embodiment, it is not necessary to perform a machining simulation each time actual machining is performed, and resources can be reduced compared to the technology disclosed in Patent Document 1.

[0159] While this disclosure has been described in detail, it is not limited to the individual embodiments described above. These embodiments can be added, replaced, modified, partially deleted, etc., in any way that does not depart from the gist of this disclosure or from the spirit of this disclosure derived from the claims and their equivalents. Furthermore, these embodiments can be implemented in combination. For example, the order of operations and processes in the embodiments described above are given as examples only and are not limited thereto. The same applies when numerical values ​​or mathematical formulas are used in the description of the embodiments described above.

[0160] The following additional information is disclosed regarding the above embodiments and modifications. (Note 1) The machining load determination system (10) is A machining unit (12) has movable parts (134, 136) on which a tool (T) or workpiece (W) is provided, and performs machining on the workpiece (W) by moving the tool (T) and the workpiece (W) relative to each other based on operating data, A simulation unit (14) performs a machining simulation of the virtual workpiece (Ws) by moving the virtual tool (Ts) and the virtual workpiece (Ws) relative to each other based on the operation data in a virtual space (VS) which includes virtual tools (Ts), virtual workpieces (Ws), and virtual movable parts (134s, 136s) corresponding to the tool (T), the workpiece (W), and the movable parts (134, 136), respectively. A virtual load acquisition unit (18) acquires virtual load information generated in the virtual movable parts (134s, 136s) obtained by the machining simulation performed by the simulation unit (14), A load acquisition unit (16) acquires actual load information generated on the movable parts (134, 136) obtained by the processing performed by the actual processing unit (12), A load information determination unit (22) compares the virtual load information with the actual load information and determines whether or not there is a difference between the two pieces of information. Equipped with, The simulation unit (14) calculates the virtual load information and comparison point identification data that identifies the points where the virtual load information and the actual load information are compared. The virtual load acquisition unit (18) acquires the virtual load information in association with the comparison location identification data, The actual load acquisition unit (16) acquires the actual load information in association with the comparison location identification data, The load information determination unit (22) compares the virtual load information and the actual load information based on the comparison location identification data.

[0161] (Note 2) In the above processing load determination system (10), The comparison location identification data for the actual load information includes at least one of the position information or time information of the movable parts (134, 136), The comparison point identification data for the virtual load information includes at least one of the position information, time information, or operation data of the virtual movable parts (134s, 136s).

[0162] (Note 3) In the above processing load determination system (10), The actual load information includes the energy generated in the movable parts (134, 136) when processing the workpiece (W). The virtual load information includes the energy generated in the virtual movable parts (134s, 136s) when the virtual workpiece (Ws) is processed.

[0163] (Note 4) In the above processing load determination system (10), The aforementioned actual load information is contact information indicating whether or not the tool (T) and the workpiece (W) are in contact. The virtual load information is contact information indicating whether or not the virtual tool (Ts) and the virtual workpiece (Ws) are in contact.

[0164] (Note 5) In the above processing load determination system (10), The load information determination unit (22) performs the determination in real time while the actual machining unit (12) is operating.

[0165] (Note 6) In the above processing load determination system (10), If the load information determination unit (22) determines that there is a difference between the virtual load information and the actual load information, the actual machining unit (12) performs at least one of the following actions: limiting the output for operating the movable parts (134, 136), performing a preset retraction operation of the movable parts (134, 136), or immediately slowing down and stopping the operation of the movable parts (134, 136).

[0166] (Note 7) In the above processing load determination system (10), The simulation unit (14) performs the machining simulation based on the operating data, which includes preconditions relating to the virtual tool (Ts), the virtual workpiece (Ws), and the virtual movable parts (134s, 136s). If the load information determination unit (22) determines that there is a difference between the virtual load information and the actual load information, the operation data identifies the process where these differences exist based on the comparison point identification data, and the preconditions for the machining simulation are changed.

[0167] (Note 8) In the above processing load determination system (10), The aforementioned actual load information is contact information indicating whether or not the tool (T) and the workpiece (W) are in contact. The virtual load information is contact information indicating whether or not the virtual tool (Ts) and the virtual workpiece (Ws) are in contact. The comparison location identification data for the actual load information includes the position information of the movable parts (134, 136), The comparison location identification data for the virtual load information includes the position information of the virtual movable parts (134s, 136s), The simulation unit (14) performs the machining simulation based on the operating data, which includes preconditions relating to the virtual tool (Ts), the virtual workpiece (Ws), and the virtual movable parts (134s, 136s). If the load information determination unit (22) determines that there is a difference between the virtual load information and the actual load information, the difference between the machine coordinates where the tool (t) and the workpiece W) come into contact in the actual machining unit (12) and the machine coordinates where the virtual tool (Ts) and the virtual workpiece (Ws) come into contact in the simulation unit (14) is calculated. The aforementioned difference is used as the correction amount for the virtual tool (Ts), and the preconditions for the virtual tool (Ts) are changed.

[0168] (Note 9) In the above processing load determination system (10), The simulation unit (14) performs the machining simulation based on the operation data before the actual machining unit (12) starts operating, and calculates the comparison location data and the virtual load information.

[0169] (Note 10) In the above processing load determination system (10), The virtual load acquisition unit (18) includes at least one of the comparison point identification data and the virtual load information in the operation data.

[0170] (Note 11) In the above processing load determination system (10), The system includes a display unit (28) that displays comparison point identification data, which the load information determination unit (22) has determined to have a difference between the virtual load information and the actual load information, in a different display mode corresponding to the difference.

[0171] (Note 12) In the above processing load determination system (10), The load information determination unit (22) extracts and compares only the virtual load information and the actual load information for a specific section in the comparison location identification data. [Explanation of symbols]

[0172] 10. Machining load determination system 12 Actual Machining Section 14. Simulation Department 16 Actual load acquisition unit 18. Virtual load acquisition unit 20 Memory section 22 Load information judgment section 24 Operation Control Unit 26 Correction section 28 Display section 100 Industrial Machinery Systems 110 Numerical control device 120 Drive unit 130 Machine Tools (Industrial Machinery) 132 Motor 134 Mounting part (movable part) 134s Virtual mounting part (virtual movable part) 136 Table (movable part) 136s Virtual Table (Virtual Moving Part) T-tool Ts Virtual Tool VS Virtual Space W Workpiece (workpiece) Ws Virtual Work (Virtual Machining Part)

Claims

1. An actual machining unit having a movable part equipped with a tool or workpiece, which performs machining on the workpiece by moving the tool and the workpiece relative to each other based on operating data, A simulation unit performs a machining simulation of a virtual workpiece by relatively moving the virtual tool and the virtual workpiece in a virtual space that includes a virtual tool, a virtual workpiece, and a virtual movable part corresponding to the tool, the workpiece, and the movable part, respectively, based on the operating data. A virtual load acquisition unit that acquires virtual load information generated in the virtual movable part obtained by the machining simulation performed by the simulation unit, A load acquisition unit that acquires actual load information generated in the movable part obtained by the processing by the actual processing unit, A load information determination unit compares the virtual load information with the actual load information and determines whether or not there is a difference between the two pieces of information. Equipped with, The simulation unit calculates the virtual load information and comparison point identification data that identifies the points where the virtual load information and the actual load information are compared. The virtual load acquisition unit acquires the virtual load information in association with the comparison location identification data, The actual load acquisition unit acquires the actual load information in association with the comparison location identification data, The load information determination unit compares the virtual load information and the actual load information based on the comparison location identification data. The actual load information is contact information indicating whether or not the tool and the workpiece are in contact. The virtual load information is contact information indicating whether or not the virtual tool and the virtual workpiece are in contact. Machining load determination system.

2. The comparison location identification data for the actual load information includes at least one of the position information or time information of the movable part. The comparison location identification data for the virtual load information includes at least one of the position information, time information, or operation data of the virtual movable part. The processing load determination system according to claim 1.

3. The machining load determination system according to claim 1 or 2, wherein the load information determination unit performs the determination in real time during the operation of the actual machining unit.

4. The machining load determination system according to claim 1 or 2, wherein if the load information determination unit determines that there is a difference between the virtual load information and the actual load information, the actual machining unit performs at least one of the following: limiting the output for operating the movable part, performing a preset retraction operation of the movable part, or immediately decelerating and stopping the operation of the movable part.

5. The simulation unit performs the machining simulation based on the operating data, which includes preconditions relating to the virtual tool, the virtual workpiece, and the virtual movable part. If the load information determination unit determines that there is a difference between the virtual load information and the actual load information, the system for determining the processing load according to claim 1 or 2, which identifies the process in the operation data where there is a difference based on the comparison point identification data and changes the preconditions for the processing simulation.

6. The comparison location identification data for the actual load information includes the position information of the movable part. The comparison location identification data for the virtual load information includes the position information of the virtual movable part, The simulation unit performs the machining simulation based on the operating data, which includes preconditions relating to the virtual tool, the virtual workpiece, and the virtual movable part. If the load information determination unit determines that there is a difference between the virtual load information and the actual load information, the difference between the machine coordinates where the tool and the workpiece come into contact in the actual machining unit and the machine coordinates where the virtual tool and the virtual workpiece come into contact in the simulation unit is calculated. The aforementioned difference is used as the correction amount for the virtual tool to change the preconditions of the virtual tool. The processing load determination system according to claim 1 or 2.

7. The machining load determination system according to claim 1 or 2, wherein the simulation unit performs the machining simulation based on the operation data before the actual machining unit is operated, and calculates the comparison location identification data and the virtual load information.

8. The processing load determination system according to claim 2, wherein the virtual load acquisition unit includes at least one of the comparison location identification data and the virtual load information in the operation data.

9. The processing load determination system according to claim 1 or 2, further comprising a display unit that displays comparison location identification data, which the load information determination unit has determined to have a difference between the virtual load information and the actual load information, in a different display mode corresponding to the difference.

10. The processing load determination system according to claim 1 or 2, wherein the load information determination unit extracts and compares only the virtual load information and the actual load information for a specific section in the comparison location identification data.

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