Polishing tool holder, polishing tool, and polishing system

Abstract

A polishing tool (1) stores and holds, in a storage unit (52) of a polishing tool holder (4), a reference dimension (M) which is the initial dimension of a linear abrasive material (2), the number of polishing operations, and a wear pattern (P) in which the amount of wear generated by one polishing operation is associated with the number of polishing operations. When a rotation detector (53) detects a rotation state, a control unit (51) of the polishing tool holder (4) adds 1 to the number of polishing operations to update the number of polishing operations, and acquires the amount of wear by referring to the wear pattern (P) on the basis of the updated number of polishing operations. In addition, when the control unit (51) detects the end of the rotation state, the control unit (51) performs an abrasive material ejection operation in which a motor is driven to operate a movement mechanism (22) so that a polishing brush (3) is moved in the axial direction by a distance corresponding to the amount of wear.

Description

Technical Field

[0001] The present invention relates to an abrasive tool holder that removably holds an abrasive tool such as a polishing brush. The present invention also relates to an abrasive tool including an abrasive tool and an abrasive tool holder. Further, the present invention relates to a polishing system having an abrasive tool and a cloud computer connected to the abrasive tool via a network.

Background Art

[0002] An abrasive tool holder that removably holds a polishing brush is described in Patent Document 1. In this document, the abrasive tool holder has a shank, a sleeve located in front of the shank in the axial direction of the shank, and a shaft extending coaxially with the shank inside the sleeve. The shaft is relatively rotatable about the axis with respect to the shank and the sleeve. Further, the abrasive tool holder includes a bolt portion provided on the shaft inside the sleeve and a nut screwed onto the bolt portion. The abrasive tool is a polishing brush and includes a plurality of linear abrasives arranged in parallel with the length direction oriented in the axial direction of the shank, and an abrasive holder that holds one end in the axial direction of the plurality of linear abrasives. The abrasive tool is held by the abrasive tool holder with the abrasive holder connected to the nut. In a state where the abrasive tool is held by the abrasive tool holder, the other ends of the plurality of linear abrasives protrude forward from the sleeve.

[0003] The abrasive tool holder of this document has a nut movement mechanism that moves the nut axially along the bolt portion. The nut movement mechanism includes a nut rotation restriction mechanism that restricts relative rotation of the nut with respect to the sleeve, and an operation member for relatively rotating the shaft with respect to the sleeve. The operation member is a gear fixed coaxially to the shaft. The gear includes a gear portion exposed outside the abrasive tool holder.

[0004] When polishing a workpiece, the polishing tool is connected to the spindle of the machine tool. The machine tool rotates the polishing tool and brings it close to the workpiece, bringing the abrasive material into contact with the surface to be polished. Once the polishing of the surface is complete, the machine tool moves the polishing tool away from the workpiece and stops the rotation of the polishing tool.

[0005] According to the same document, when the abrasive material wears down during the grinding operation, the machine tool performs an abrasive material ejection operation. In the abrasive material ejection operation, the machine tool moves the grinding tool, which is in a stopped rotational state, to the abrasive material ejection amount adjustment position. The machine tool also engages the rack gear located at the abrasive material ejection amount adjustment position with the gear portion of the gear exposed from the grinding tool holder, and moves the grinding tool by a predetermined amount. As a result, the shaft of the grinding tool holder rotates, and the nut moves forward in the axial direction. Consequently, the grinding tool connected to the nut moves forward, and the abrasive material is ejected forward from the sleeve. [Prior art documents] [Patent Documents]

[0006] [Patent Document 1] International Publication No. 2015 / 178273 [Overview of the Initiative] [Problems that the invention aims to solve]

[0007] In manufacturing lines, polishing processes are sometimes performed in which multiple identical parts (workpieces) are polished one after another in succession. In other words, manufacturing lines sometimes perform polishing processes in which the same polishing operation is repeated while replacing the parts (workpieces).

[0008] When performing such a polishing process with the polishing tool described above, first, the first workpiece is placed in a predetermined machining position, and the polishing operation is performed on the first workpiece. During the polishing operation, the machine tool rotates the polishing tool 1 and brings it closer to the first workpiece, setting the distance between the machine tool's spindle and the first workpiece to a set distance. The set distance is the distance at which the abrasive material of the polishing tool held in the polishing tool holder contacts the surface of the workpiece to be polished with a predetermined depth of cut. The machine tool also moves the polishing tool along a predetermined polishing path while maintaining the distance between the spindle and the first workpiece at the set distance. After the polishing operation on the first workpiece is completed, the machine tool moves the polishing tool holder away from the first workpiece and replaces the first workpiece in the machining position with the second workpiece. The machine tool also performs an abrasive material ejection operation. That is, the machine tool moves the polishing tool to the abrasive material ejection amount adjustment position, engages the rack gear with the gear portion of the gear of the polishing tool holder, moves the polishing tool, and rotates the gear. As a result, the shaft of the abrasive holder rotates, causing the abrasive to move axially by the amount corresponding to the rotation of the gear, and the abrasive material to protrude forward.

[0009] Next, the polishing operation is performed on the second workpiece. That is, the machine tool rotates the polishing tool and brings the polishing tool closer to the second workpiece, setting the distance between the machine tool's spindle and the second workpiece to a set distance. Then, while maintaining the distance between the spindle and the first workpiece at the set distance, the machine tool moves the polishing tool along a predetermined polishing path. After the polishing operation on the second workpiece is completed, the machine tool moves the polishing tool holder away from the second workpiece and replaces the second workpiece in the machining position with the third workpiece. The machine tool also performs an abrasive material ejection operation. That is, the machine tool moves the polishing tool to the abrasive material ejection amount adjustment position, engages the rack gear with the gear portion of the gear of the polishing tool holder, moves the polishing tool, and rotates the gear. As a result the shaft of the polishing tool holder rotates, the polishing tool moves axially by an amount corresponding to the rotation of the gear, and the abrasive material is ejected forward. After that, the polishing operation is performed on the third workpiece. In the polishing process, this series of actions is repeated until there is no more workpiece to be polished.

[0010] Thus, when conventional polishing tools are used in the polishing process, it is necessary to move the polishing tool to the abrasive material protrusion adjustment position and perform the abrasive material protrusion operation after each polishing operation of a workpiece is completed. Consequently, there is a problem in that the cycle time required to polish a single workpiece becomes long.

[0011] Furthermore, for example, if the abrasive material is a linear abrasive, even when performing the same polishing operation on parts of the same shape, the amount of abrasive material worn down in a single polishing operation will differ depending on the length of the abrasive material (the length dimension of the linear abrasive material). Therefore, in the above polishing process, after each polishing operation on a workpiece is completed, the amount of protrusion of the abrasive material must be changed based on the length dimension of the abrasive material at the start of polishing that workpiece. In other words, the amount of rotation of the gear must be adjusted based on the length dimension of the linear abrasive material at the start of polishing that workpiece to protrude the abrasive material by an amount corresponding to the amount of wear.

[0012] If the amount of abrasive material protrusion due to the abrasive material ejection operation does not correspond to the amount of abrasive material worn down by the polishing operation of the previous workpiece, then when the distance between the machine tool spindle and the second workpiece is set to a predetermined distance at the start of polishing the next workpiece, the amount of abrasive material cut into the next workpiece will differ from the amount of abrasive material cut into the previous workpiece. Consequently, variations in polishing accuracy will occur among multiple workpieces being polished in the polishing process.

[0013] In view of the above problems, the objective is to provide a polishing tool holder that automatically extends the abrasive material when performing a polishing process in which the same polishing operation is performed multiple times in succession while changing workpieces, and that can prevent or suppress variations in polishing accuracy for each workpiece. Furthermore, the objective is to provide a polishing tool consisting of such a polishing tool holder and a polishing tool. In addition, the objective is to provide a polishing system that automatically extends the abrasive material of the polishing tool when performing a polishing process in which the same polishing operation is performed multiple times in succession while changing workpieces, and that can prevent or suppress variations in polishing accuracy for each workpiece. [Means for solving the problem]

[0014] To solve the above problems, the present invention provides a polishing tool holder comprising a shank connected to the spindle of a machine tool, an abrasive material holder, and an abrasive material held in the abrasive material holder, a support mechanism that supports the polishing tool so as to be movable in the axial direction of the shank, and a drive source and a moving mechanism that moves the polishing tool in the axial direction, wherein the polishing tool holder comprises a control unit that drives and controls the drive source, a storage unit connected to the control unit, a rotation detector that detects the rotation state being rotated by the machine tool, and a power supply that supplies power to the drive source and the control unit, wherein the storage unit stores a reference dimension which is the dimension of the abrasive material at the time the polishing tool is supported by the support mechanism, the number of polishing operations which is the number of times the rotation detector has detected the rotation state, and the abrasive material of the reference dimension The control unit is characterized by storing and maintaining a wear pattern associated with the amount of wear caused by a single polishing operation to polish a workpiece and the number of polishing operations, and updating the polishing operation count in the storage unit when the rotation detector detects the rotation state by adding 1 to the number of polishing operations, a wear amount acquisition unit that obtains the amount of wear by referring to the wear pattern based on the calculated number of polishing operations, and a drive control unit that, when it detects that the rotation state has ended based on the output from the rotation detector, drives the drive source to operate the moving mechanism and performs an abrasive material ejection operation to move the polishing tool to the opposite side of the shank by a distance corresponding to the amount of wear.

[0015] According to the present invention, the polishing tool holder includes a drive source, a moving mechanism for moving a polishing tool supported by a support mechanism, a control unit for controlling the drive source, and a power supply for supplying power to the drive source and the control unit. Therefore, the polishing tool holder can move the polishing tool in the axial direction by driving the moving mechanism through the drive control of the drive source by the control unit. Thus, the polishing tool holder can automatically perform an abrasive material ejection operation in which the abrasive material is ejected on the opposite side of the shank by moving the polishing tool in the axial direction.

[0016] Furthermore, according to the present invention, the memory unit stores a reference dimension, which is the dimension of the abrasive material at the time the polishing tool is supported by the support mechanism; the number of polishing operations, which is the number of times the rotation detector has detected a rotation state; and a wear pattern, which is associated with the amount of wear and the number of polishing operations when the abrasive material of the reference dimension is polished by one polishing operation on a workpiece. When the rotation detector detects a rotation state, the control unit adds 1 to the number of polishing operations to update the number of polishing operations, and obtains the amount of wear by referring to the wear pattern based on the updated number of polishing operations. Then, when the control unit detects that the rotation state has ended based on the output from the rotation detector, it drives the drive source to operate the moving mechanism and moves the polishing tool axially by a distance corresponding to the amount of wear, performing an abrasive material ejection operation to eject the abrasive material.

[0017] Here, for example, if the abrasive material is a linear abrasive, even when performing the same polishing operation to polish parts of the same shape, the amount of abrasive material worn in one polishing operation will differ depending on the length of the abrasive material at the start of the polishing operation. In other words, if the abrasive material is a linear abrasive, the shorter the length of the abrasive material at the start of the polishing operation, the greater the rigidity of the abrasive material, and therefore the greater the amount of wear in one polishing operation. Consequently, if the amount of abrasive material protruding by the abrasive material protrusion operation (the amount of movement of the polishing tool) is kept constant, the amount of cutting of the abrasive material into the next workpiece will change, resulting in variations in the accuracy of the polishing process among multiple workpieces being polished consecutively. In contrast, the polishing tool holder of the present invention obtains the amount of abrasive material wear from the wear pattern stored in the memory unit after each polishing operation is completed. The wear pattern associates the amount of wear that occurs in one polishing operation with the number of polishing operations for an abrasive material of a standard dimension at the time it is supported by the support mechanism. Therefore, by referring to the wear pattern based on the number of polishing operations to obtain the amount of wear, the obtained amount of wear will reflect the amount of wear of the abrasive material, which changes depending on the length dimension of the linear abrasive material at the start of the polishing operation. Thus, the amount of abrasive material protrusion due to the abrasive material protrusion operation can be made to correspond to the amount of wear of the abrasive material due to the polishing of the previous workpiece. Accordingly, by holding the polishing tool in the polishing tool holder of the present invention, in a polishing process in which the same polishing operation is performed multiple times in succession while changing workpieces, the protrusion of the abrasive material can be performed automatically, and variations in the polishing accuracy for each workpiece can be prevented or suppressed.

[0018] In the present invention, the drive control unit may perform the abrasive material ejection operation when it detects the end of the rotation state. That is, when the polishing operation for one workpiece is completed, the abrasive material ejection operation may be performed continuously.

[0019] In the present invention, when the drive control unit detects the end of the rotation state, it may perform the abrasive material ejection operation when the rotation detector next detects the rotation state. That is, after the polishing operation for one workpiece is completed, the abrasive material ejection operation may be performed when the machine tool rotates the polishing tool for the polishing operation of the next workpiece.

[0020] In the present invention, the control unit may be equipped with a notification unit, and the control unit may be equipped with an abrasive material length dimension calculation unit that, when the amount of wear is first acquired, calculates the dimension obtained by subtracting the amount of wear from the reference dimension as the abrasive material length dimension and stores it in the storage unit, and thereafter, each time the amount of wear is acquired, calculates the dimension obtained by subtracting the amount of wear from the abrasive material length dimension as a new abrasive material length dimension and updates the abrasive material length dimension in the storage unit, a replacement determination unit that, each time the abrasive material length dimension is calculated, determines whether or not the polishing tool needs to be replaced based on the abrasive material length dimension and the reference dimension, and a replacement notification unit that, when it is determined that the polishing tool needs to be replaced, drives the notification unit to notify that the polishing tool needs to be replaced. That is, each time the polishing operation is completed, the control unit calculates the abrasive material length dimension of the abrasive material at the time of completion and determines whether or not replacement is necessary based on the abrasive material length dimension and the reference dimension. Then, if the control unit determines that replacement is necessary, it drives the notification unit to notify that the polishing tool needs to be replaced.

[0021] In the present invention, a communication unit is provided for communicating with an external device, and the reference dimensions and the wear pattern are input to the control unit via the communication unit and stored in the storage unit. In this case, the communication unit may perform wireless communication with the external device. Alternatively, the communication unit may perform wired communication with the external device.

[0022] In the present invention, the rotation detector may be an acceleration sensor.

[0023] The rotation detector can be a vibration sensor. When the grinding tool holder is rotated by a machine tool, vibration occurs in the grinding tool holder. Therefore, by detecting this vibration, the rotation state of the grinding tool holder can be detected.

[0024] In the present invention, the rotation detector can include a conductive member that moves by centrifugal force, and the conductive member can be a switch that opens and closes a circuit.

[0025] In the present invention, the support mechanism includes a connecting member having a through hole penetrating in the axial direction, and a shaft member that is coaxial with the shank, penetrates the through hole, and extends in the axial direction. The drive source is a motor, and the moving mechanism includes a rotational support mechanism that rotatably supports the shaft member around the axis, a female thread provided on the inner peripheral surface of the through hole, a male thread provided on the outer peripheral surface of the shaft member and screwed with the female thread, a driving force transmission mechanism that transmits the rotation of the motor to the shaft member, a sleeve that guides the connecting member in the axial direction on the outer peripheral side of the connecting member and the shaft member, and a rotation restricting mechanism that restricts the rotation of the connecting member and the shaft member. The grinding tool is connected to the abrasive holder so that a part of the abrasive protrudes outward from the sleeve, and the control unit can drive the motor to rotate the shaft member to move the connecting member in the axial direction. The connecting member Next, the grinding tool of the present invention has the above-described grinding tool holder, a grinding tool including an abrasive holder and an abrasive held by the abrasive holder. The abrasive includes a plurality of linear abrasives arranged in parallel with their length directions facing the axial direction. The abrasive holder holds one end of the plurality of linear abrasives in the axial direction, and the grinding tool is supported by the grinding tool holder and contacts the other end of the plurality of linear abrasives with a workpiece to grind the workpiece.

[0026]

[0027] ​Furthermore, the polishing tool of the present invention comprises the above-mentioned polishing tool holder and a polishing tool comprising an abrasive material holder and an abrasive material held in the abrasive material holder, wherein the abrasive material is an elastic grinding wheel, the abrasive material holder holds one end of the elastic grinding wheel in the axial direction, and the polishing tool is supported by the polishing tool holder and polishes the workpiece by bringing the other end of the elastic grinding wheel into contact with the workpiece. In this case, the elastic grinding wheel may contain an elastic foam, a polymer, and abrasive grains.

[0028] Furthermore, the polishing tool of the present invention comprises the above-mentioned polishing tool holder and a polishing tool comprising an abrasive material holder and an abrasive material held in the abrasive material holder, wherein the abrasive material is a rigid grinding wheel, the abrasive material holder holds one end of the grinding wheel in the axial direction, and the polishing tool is supported by the polishing tool holder and polishes the workpiece by bringing the other end of the grinding wheel into contact with the workpiece.

[0029] Next, the present invention relates to a polishing tool comprising an abrasive material holder and an abrasive material held in the abrasive material holder, a shank connected to the spindle of a machine tool, a support mechanism that supports the polishing tool so as to be movable in the axial direction of the shank, and a drive source, and a polishing tool holder having a movement mechanism for moving the polishing tool in the axial direction, and a cloud computer that is communicably connected to the polishing tool holder via a network, wherein the polishing tool holder comprises a control unit that drives the drive source based on a drive command, a rotation detector that detects the rotation state being rotated by the machine tool, a power supply that supplies power to the drive source and the control unit, and a communication unit that communicates with the cloud computer, the communication unit transmits the output from the rotation detector to the cloud computer and receives the drive command from the cloud computer and inputs it to the control unit, and the cloud computer determines the dimensions of the abrasive material at the time the polishing tool is supported by the support mechanism. The polishing tool control unit comprises a storage unit that stores a reference dimension, the number of polishing operations which is the number of times the rotation detector has detected the rotation state, and a wear pattern associated with the amount of wear and the number of polishing operations when an abrasive material of the reference dimension is worn down in one polishing operation to polish a workpiece, and a polishing tool control unit, wherein the polishing tool control unit comprises a polishing operation count update unit that updates the polishing operation count in the storage unit by adding 1 to the polishing operation count when the rotation detector detects the rotation state, an amount of wear acquisition unit that obtains the amount of wear by referring to the wear pattern based on the polishing operation count once the number of polishing operations has been calculated, a drive command issuing unit that issues a drive command to drive the drive source to operate the moving mechanism and perform an abrasive material ejection operation which moves the polishing tool to the opposite side of the shank by a distance corresponding to the amount of wear once the drive command has been issued.

[0030] The polishing system of the present invention comprises a polishing tool consisting of a polishing tool holder and a polishing tool, and a cloud computer connected to the polishing tool holder via a network. The polishing tool control unit of the cloud computer includes a drive command issuing unit that issues drive commands. The polishing tool holder includes a drive source, a moving mechanism that moves the polishing tool supported by a support mechanism, a control unit that controls the drive source based on the drive command, and a power supply that supplies power to the drive source and the control unit. Therefore, the polishing system can drive the moving mechanism of the polishing tool holder based on the drive command from the cloud computer to move the polishing tool in the axial direction. Thus, the polishing tool can automatically perform an abrasive material ejection operation in which the abrasive material is ejected on the opposite side of the shank by moving the polishing tool in the axial direction.

[0031] Furthermore, in this invention, a cloud computer that can communicate with the polishing tool holder obtains the amount of abrasive material wear from the wear pattern stored in the cloud computer's memory after each polishing operation is completed in the polishing tool. In addition, once the cloud computer obtains the amount of wear, it issues a drive command to the polishing tool holder to drive the drive source of the polishing tool and operate the movement mechanism to perform an abrasive material ejection operation, moving the polishing tool to the opposite side of the shank by a distance corresponding to the amount of wear, and transmits this command to the polishing tool holder. Upon receiving the drive command, the polishing tool drives the drive source and performs the abrasive material ejection operation. Here, the wear pattern is a combination of the amount of wear that occurs in one polishing operation and the number of polishing operations for the abrasive material of a reference dimension at the time it is supported by the support mechanism. Therefore, if the amount of wear is obtained by referring to the wear pattern based on the number of polishing operations, the obtained amount of wear will reflect the amount of abrasive material wear that changes depending on the length dimension of the linear abrasive material at the start of the polishing operation. Thus, the amount of abrasive material ejection by the abrasive material ejection operation can be made to correspond to the amount of wear that occurred due to the polishing of the previous workpiece. Therefore, according to the polishing system of the present invention, in a polishing process in which the same polishing operation is performed multiple times in succession while changing the workpiece, the protrusion of the abrasive material is performed automatically, and variations in the accuracy of the polishing process for each workpiece can be prevented or suppressed.

[0032] In the present invention, the drive command issuing unit may issue the drive command when it detects the end of the rotation state. That is, when the polishing operation on one workpiece is completed, the cloud computer may issue and transmit a drive command to cause the polishing tool to perform an abrasive material ejection operation.

[0033] In the present invention, when the drive command issuing unit detects the end of the rotation state, it may issue the drive command when the rotation detector next detects the rotation state. That is, after the polishing operation on one workpiece is completed, when the machine tool rotates the polishing tool for the polishing operation on the next workpiece, the cloud computer may issue and transmit a drive command to cause the polishing tool to perform an abrasive material ejection operation.

[0034] In the present invention, the polishing tool holder includes a notification unit, the polishing tool control unit includes an abrasive material length dimension calculation unit that, when the amount of wear is first acquired, calculates the dimension obtained by subtracting the amount of wear from the reference dimension as the abrasive material length dimension and stores it in the storage unit, and thereafter, each time the amount of wear is acquired, calculates the dimension obtained by subtracting the amount of wear from the abrasive material length dimension as a new abrasive material length dimension and updates the abrasive material length dimension in the storage unit, the replacement determination unit that, each time the abrasive material length dimension is calculated, determines whether or not the polishing tool needs to be replaced based on the abrasive material length dimension and the reference dimension, and a notification command issuing unit that, when it is determined that the polishing tool needs to be replaced, drives the notification unit to issue a notification command indicating that the polishing tool needs to be replaced, and the command transmission unit can transmit the notification command to the polishing tool holder when the notification command is issued.

[0035] In the present invention, the support mechanism comprises a connecting member having a through hole penetrating in the axial direction, and a shaft member coaxial with the shank and penetrating the through hole and extending in the axial direction, the drive source is a motor, the moving mechanism comprises a rotation support mechanism that supports the shaft member so as to be rotatable around the axis, a female screw provided on the inner circumferential surface of the through hole, a male screw provided on the outer circumferential surface of the shaft member and screwing into the female screw, a drive force transmission mechanism that transmits the rotation of the motor to the shaft member, a sleeve that guides the connecting member in the axial direction on the outer circumferential side of the connecting member and the shaft member, and a rotation restricting mechanism that restricts the joint rotation of the connecting member and the shaft member, and the abrasive tool comprises the abrasive material holder The connecting member The unit is connected to the shaft member, causing a portion of the abrasive material to protrude outward from the sleeve, and the control unit drives the motor to rotate the shaft member, thereby moving the connecting member in the axial direction.

[0036] In the present invention, the polishing tool comprises a first polishing tool and a second polishing tool that are communicably connected to the cloud computer via a network, and the cloud computer, as the polishing tool control unit, includes a first polishing tool control unit that receives the output from the rotation detector of the first polishing tool and transmits the drive command to the first polishing tool, and a second polishing tool control unit that receives the output from the rotation detector of the second polishing tool and transmits the drive command to the second polishing tool. 2nd The system may include a polishing tool control unit. In this way, if the machine tool consists of a first machine tool and a second machine tool that perform the same polishing process, and a first polishing tool is connected to the first machine tool and a second polishing tool is connected to the second machine tool, these multiple polishing tools can be driven and controlled by a single cloud computer. Furthermore, the cloud computer's memory DepartmentBased on a single polishing pattern stored in memory, the amount of abrasive wear can be obtained, and the abrasive material ejection operation of each polishing tool can be performed. Furthermore, changes to the wear pattern of each polishing tool can be performed collectively by updating the wear pattern in the memory unit. In addition, the wear status of the abrasive materials of multiple polishing tools can be monitored on the cloud computer side. Therefore, multiple polishing tools connected to each machine tool can be centrally managed. Moreover, in this way, the output of the rotation sensors of multiple polishing tools is collected on the cloud computer. Therefore, the operating status of each machine tool can be monitored on the cloud computer side based on the rotation status of each polishing tool. [Brief explanation of the drawing]

[0037] [Figure 1] This is a perspective view of the polishing tool according to Example 1 to which the present invention is applied. [Figure 2] This is a perspective view of the polishing brush, which is the polishing tool of the polishing tool in Example 1. [Figure 3] Figure 1 is a schematic diagram illustrating the general structure of the polishing tool. [Figure 4] This is an explanatory diagram of the polishing process using polishing tools. [Figure 5] This is an explanatory diagram of the wear pattern stored in the memory section of the polishing tool holder. [Figure 6] This is a flowchart of the polishing process. [Figure 7] This is a flowchart showing the operation of the polishing tool holder during the polishing process. [Figure 8] This is a perspective view of the polishing tool according to Example 2, to which the present invention is applied. [Figure 9] This is a perspective view of the polishing tool of the polishing tool of Example 2. [Figure 10] This is an explanatory diagram of the wear pattern stored by the polishing tool of Example 2. [Figure 11] This is a perspective view of the polishing tool according to Example 3, to which the present invention is applied. [Figure 12] This is an explanatory diagram of the wear pattern stored by the polishing tool of Example 3. [Figure 13]This is an explanatory diagram of a polishing system to which the present invention is applied. [Figure 14] This is a flowchart illustrating the operation of the polishing system during the polishing process. [Figure 15] This is an explanatory diagram of a polishing system equipped with multiple polishing tools. [Modes for carrying out the invention]

[0038] An embodiment of the present invention, a polishing tool, will be described below with reference to the drawings.

[0039] (Example 1) Figure 1 is an external perspective view of an example 1 polishing tool to which the present invention is applied. Figure 2 is a perspective view of the polishing brush attached to the polishing tool. The polishing brush in Figure 2 is unused. Figure 3 is an explanatory diagram showing the schematic structure of the polishing tool of Figure 1. In Figure 3, the polishing tool is shown cut along its axis. Figure 4 is an explanatory diagram of the polishing operation using the polishing tool.

[0040] (polishing tools) As shown in Figure 1, the polishing tool 1 comprises a polishing brush 3 (polishing tool) equipped with multiple linear abrasive materials 2 (abrasives), and a polishing tool holder 4 that detachably holds the polishing brush 3. The polishing tool holder 4 comprises a shank 6 connected to a machine tool 5 and a sleeve 7 coaxial with the shank 6. A large-diameter portion 8, which is larger in diameter than the shank 6 and sleeve 7, is provided between the shank 6 and sleeve 7. The sleeve 7 has a flange 7a that widens outward at its rear end. The flange 7a defines the front end surface of the large-diameter portion 8. The polishing brush 3 is held in the polishing tool holder 4 with the ends of the linear abrasive materials 2 protruding forward from the sleeve 7.

[0041] As shown in Figure 4, the polishing tool 1 is used by connecting the shank 6 of the polishing tool holder 4 to the spindle 5a of the machine tool 5. When performing a polishing operation on the workpiece W, the machine tool 5 rotates the polishing tool 1 around the axis of the shank 6. The machine tool 5 also brings the polishing tool 1 close to the workpiece W and sets the distance between the spindle 5a and the surface S to be polished on the workpiece W to a set distance D. The set distance D is the distance at which the linear abrasive material 2 of the polishing brush 3 contacts the surface S to be polished on the workpiece W with a predetermined depth of cut E. The machine tool 5 then performs polishing for a predetermined time while maintaining the distance between the spindle 5a and the workpiece W at the set distance D and moving the polishing tool 1 along a predetermined polishing path along the surface S to be polished. When the polishing operation on the workpiece W is completed, the machine tool 5 moves the polishing tool 1 away from the workpiece W and stops the rotation of the polishing tool 1.

[0042] In the following explanation, the direction along the axis L of the shank 6 will be referred to as the axial direction X of the grinding tool 1. Furthermore, in the axial direction X, the side where the sleeve 7 is located will be the front of the grinding tool 1, which will be referred to as the first direction X1, and the side where the shank 6 is located will be the rear of the grinding tool, which will be referred to as the second direction X2 of the grinding tool 1.

[0043] (Polishing brush) As shown in Figure 2, the polishing brush 3 has a plurality of linear abrasive materials 2 arranged in parallel, and an abrasive material holder 11 that holds one end of each of these linear abrasive materials 2. Each of the linear abrasive materials extends in the axial direction X. The linear abrasive material 2 is made by impregnating and hardening a binder resin into a bundle of inorganic long fibers such as alumina long fibers.

[0044] As shown in Figure 3, the abrasive material holder 11 is an annular member and has a holder through hole 12 extending in the axial direction X. Also, as shown in Figure 2, the abrasive material holder 11 has a plurality of abrasive material holding holes 13 on its end face 11a in the first direction X1. Each abrasive material holding hole 13 is circular. The plurality of abrasive material holding holes 13 are provided at equal angular intervals around the axis L. The plurality of abrasive material holding holes 13 surround the holder through hole 12. Multiple linear abrasive materials 2 are divided into groups of multiples and bundled together. The rear end of the bundled abrasive material bundle 14 is inserted into the abrasive material holding hole 13 and fixed to the abrasive material holder 11 with adhesive.

[0045] Furthermore, as shown in Figure 3, the abrasive holder 11 has a recess on its rear end face. The recess is coaxial with the holder through hole 12 and has a larger inner diameter than the holder through hole 12. The recess is a connecting portion 15 for holding the polishing brush 3 in the polishing tool holder 4.

[0046] (Polishing tool holder) As shown in Figure 3, the polishing tool holder 4 comprises a shank 6, a support mechanism 21 that supports the polishing brush 3 so as to be movable in the axial direction X, and a moving mechanism 22 that moves the polishing brush 3 in the axial direction X. The moving mechanism 22 is equipped with a motor 35 as its drive source. In this example, the motor 35 is a geared motor and is equipped with an encoder 35a.

[0047] The support mechanism 21 includes a connecting member 24 to which the polishing brush 3 is connected, and a shaft member 36 extending coaxially with the shank 6. The connecting member 24 has a through hole 28 that penetrates in the axial direction X. A female thread 29 is provided on the inner circumferential surface of the through hole 28. The shaft member 36 passes through the through hole 28. The sleeve 7 is located on the outer circumferential side of the connecting member 24 and the shaft member 36. The connecting member 24 is movable within the sleeve 7 in the axial direction X while being supported by the shaft member 36.

[0048] The connecting member 24 comprises a disc portion 25 and a projection 26 that protrudes from the center of the disc portion 25 in a first direction X1. The disc portion 25 has an annular opposing surface 25a that faces the inner circumferential surface 7b of the sleeve 7 with a small gap between them. The projection 26 is shaped to fit into the connecting portion 15 of the polishing brush 3. The projection 26 is the connecting portion on the connecting member side that connects the polishing brush 3 and the connecting member 24.

[0049] The polishing brush 3 is connected to the connecting member 24 with its connecting portion 15 fitted into the projection 26 of the connecting member 24. When the polishing brush 3 is connected to the connecting member 24, the through hole 28 of the connecting member 24 and the holder through hole 12 are in communication. The inner diameter of the holder through hole 12 is larger than the inner diameter of the through hole 28 of the connecting member 24. Also, when the polishing brush 3 is connected to the connecting member 24, the polishing brush 3 and the connecting member 24 become one unit. Therefore, the polishing brush 3 is supported by the support mechanism 21 in a state where it can move in the axial direction X. Here, the polishing brush 3 and the connecting member 24 do not rotate relative to each other around the axis.

[0050] The moving mechanism 22 includes a motor 35. The moving mechanism 22 also includes a rotation support mechanism 37 that supports the shaft member 36 so that it can rotate around its axis, a female screw 29 provided on the inner circumferential surface of the through hole 28 of the connecting member 24, and a male screw 36a provided on the outer circumferential surface of the shaft member 36. Furthermore, the moving mechanism 22 includes a drive force transmission mechanism 44 that transmits the rotation of the motor 35 to the shaft member 36, a sleeve 7, and a rotation restricting mechanism 40 that restricts the joint rotation of the connecting member 24 and the shaft member 36 around the axis L.

[0051] The rotational support mechanism 37 includes a radial support member 38 that rotatably supports the portion of the shaft member 36 on the side facing the second direction X2 from the outer circumference, and a thrust support member 39 that supports the shaft member 36 from the side facing the second direction X2. The radial support member 38 is disc-shaped and has a shaft hole 41 at its center through which the shaft member 36 passes in the axial direction X. The radial support member 38 is located between the drive force transmission mechanism 44 and the connecting member 24 in the axial direction X. The rotational support mechanism 37 also includes a biasing member 47 that biases the shaft member 36 against the thrust support member 39. The biasing member 47 is a coil spring and is positioned between the radial support member 38 and a second gear 46 fixed to the rear end of the shaft member 36, with the shaft member 36 passing through its center. The biasing member 47 presses the shaft member 36 against the thrust support member 39 by biasing the second gear 46 in the second direction X2.

[0052] Here, the large-diameter portion 8 of the polishing tool holder 4 has a housing 18 comprising a cylindrical portion 16 and a sealing plate portion 17 that seals the opening of the cylindrical portion 16 in a second direction X2. The shank 6 protrudes from the central portion of the sealing plate portion 17 in the second direction X2. The radial support member 38 is fixed to the cylindrical portion 16 from the side in the first direction X1 so as to seal the opening of the cylindrical portion 16 in the first direction X1. The flange 7a of the sleeve 7 is fixed to the end face of the radial support member 38 in the first direction X1. As shown in Figure 1, the annular outer peripheral surface 38a of the radial support member 38 facing radially outward constitutes the outer peripheral surface of the large-diameter portion 8 together with the outer peripheral surface of the cylindrical portion 16. As shown in Figure 3, the motor 35, thrust support member 39, and drive force transmission mechanism 44 are housed in the space inside the large-diameter portion 8, which is partitioned by the housing 18 and the radial support member 38.

[0053] In the shaft member 36, a male screw 36a is provided on the outer circumferential surface of the first direction X1 axial portion located in the first direction X1 relative to the radial support member 38. The male screw 36a can be screwed into the female screw 29 of the connecting member 24. The connecting member 24 is supported by the shaft member 36 with its female screw 29 screwed into the male screw 36a of the shaft member 36.

[0054] The drive force transmission mechanism 44 includes a first gear 45 attached to the output shaft of the motor 35 and a second gear 46 that meshes with the first gear 45. The second gear 46 is fixed coaxially with the shaft member 36 at the end portion of the shaft member 36 in a second direction X2. The rotation of the motor 35 is transmitted to the shaft member 36 via the first gear 45 and the second gear 46.

[0055] The sleeve 7 has a groove 31 on its inner circumferential surface 7b that extends in the axial direction X. The connecting member 24 has a projection 32 on a portion of the circumferential direction of its annular opposing surface 25a that protrudes outward and extends in the axial direction X. The connecting member 24 is positioned inside the sleeve 7 with the projection 32 inserted into the groove 31 of the sleeve 7. Therefore, when the connecting member 24 moves in the axial direction X, the connecting member 24 is guided along the groove 31. Furthermore, the groove 31 provided on the inner circumferential surface 7b of the sleeve 7 and the projection 32 provided on the outer circumferential surface of the connecting member 24 constitute a rotation restricting mechanism 40 that restricts the connecting member 24 and the shaft member 36 from rotating together around the axis L.

[0056] Here, the polishing brush 3 is inserted into the sleeve 7 after the abrasive material holder 11 is connected to the connecting member 24, and is held in the polishing tool holder 4. When the polishing brush 3 is held in the polishing tool holder 4, the female thread 29 of the connecting member 24 is screwed onto the male thread 36a of the shaft member 36. The shaft member 36 passes through the through hole 28 of the connecting member 24 and then extends axially in the X direction inside the holder through hole 12 of the abrasive material holder 11 of the polishing brush 3. When the polishing brush 3 is held in the polishing tool holder 4, the abrasive material holder 11 is located inside the sleeve 7, and the ends (free ends) of the multiple linear abrasive materials 2 in the first direction X1 protrude from the sleeve 7 in the first direction X1.

[0057] (Control system) As shown in Figure 3, the control system of the polishing tool holder 4 comprises a control unit 51 equipped with a CPU and a memory unit 52 connected to the control unit 51. The memory unit 52 is a rewritable non-volatile memory. A rotation detector 53 is connected to the input side of the control unit 51. The rotation detector 53 detects the rotation state of the polishing tool holder 4 being rotated by the machine tool 5. In this example, the rotation detector 53 is an acceleration sensor. A motor 35 is connected to the output side of the control unit 51. The output signal from the encoder 35a of the motor 35 is fed back to the control unit 51. In addition, a light-emitting unit 54 (notification unit) is connected to the output side of the control unit 51. The light-emitting unit 54 is equipped with an LED. Furthermore, a communication unit 55 is connected to the control unit 51. The communication unit 55 enables communication between the control unit 51 and external devices.

[0058] The memory unit 52 stores the reference dimension M, which is the dimension of the linear abrasive material 2 at the time the polishing brush 3 is supported by the support mechanism 21, and the polishing operation count, which is the number of times the rotation detector 53 detected the rotation state. In this example, the reference dimension M is the length dimension (bristle length) of the linear abrasive material 2 of the unused polishing brush 3 (see Figure 2). The length dimension of the linear abrasive material 2 is the dimension from the end face 11a of the abrasive material holder 11 in the first direction X1 to the tip 2a of the linear abrasive material 2. The initial value of the polishing operation count is "0". Here, when the machine tool 5 polishes the workpiece W, it rotates the polishing tool 1 to bring the linear abrasive material 2 into contact with the workpiece W. Also, when the polishing of the workpiece W is finished, the machine tool 5 stops the rotation of the polishing tool 1. Therefore, the number of times the polishing tool 1 has been rotated by the machine tool 5 is the number of polishing operations performed.

[0059] Furthermore, the memory unit 52 stores a wear pattern P for a linear abrasive material 2 of standard dimension M (the linear abrasive material 2 of the unused polishing brush 3), relating the amount of wear that occurs in one polishing operation to the number of polishing operations. Figure 5 shows the wear pattern P of the linear abrasive material 2 when the same polishing operation is performed multiple times while changing the workpiece W using the polishing tool 1 of this example. In Figure 5, the horizontal axis represents the number of polishing operations (times), and the vertical axis represents the amount of wear (mm). The wear pattern P was obtained by actually performing the same polishing operation multiple times consecutively using an unused polishing brush 3, changing the workpiece W, and measuring the amount of wear of the linear abrasive material 2 worn in each polishing operation. The wear pattern P is stored in the memory unit 52 in the form of a mathematical formula. Alternatively, the wear pattern P is stored in the memory unit 52 in the form of a table.

[0060] Here, in the polishing brush 3, even when performing the same polishing operation to polish parts of the same shape, the amount of abrasive material worn in one polishing operation changes depending on the length of the linear abrasive material 2 at the start of the polishing operation. The wear pattern P shown in Figure 5 reflects this change in the amount of wear due to the length of the bristles of the linear abrasive material 2. That is, when the dimensions of the linear abrasive material 2 of the polishing brush 3 are close to the standard dimension M (when the number of polishing operations is small), the linear abrasive material 2 is more likely to bend during the polishing operation. Therefore, when the number of polishing operations is small, the amount of wear of the linear abrasive material 2 in one polishing operation is relatively small. Subsequently, as the number of polishing operations increases and the linear abrasive material 2 becomes shorter, the bending of the linear abrasive material 2 during the polishing operation becomes constant, and the amount of wear of the linear abrasive material 2 in one polishing operation does not change. After that, as the number of polishing operations increases and the linear abrasive material 2 becomes even shorter, the rigidity of the linear abrasive material 2 increases, and the linear abrasive material 2 no longer bends. Therefore, once the number of polishing operations exceeds a certain number, the amount of wear on the linear abrasive material 2 due to a single polishing operation tends to increase.

[0061] As shown in Figure 3, the control unit 51 includes a polishing operation count update unit 61, a wear amount acquisition unit 62, and a drive control unit 63. The control unit 51 also includes an abrasive material length dimension calculation unit 64, a replacement determination unit 65, and a replacement notification unit 66.

[0062] When the rotation detector 53 detects a rotation state, the polishing operation count update unit 61 calculates a new polishing operation count by adding 1 to the polishing operation count stored in the memory unit 52, and updates the polishing operation count in the memory unit 52. When the polishing operation count is calculated, the wear amount acquisition unit 62 acquires the wear amount by referring to the wear pattern P based on the calculated polishing operation count.

[0063] When the drive control unit 63 detects that the rotation state of the polishing tool 1 has ended based on the output from the rotation detector 53, it performs an abrasive material ejection operation. That is, when the rotation detector 53 transitions from detecting a rotation state to not detecting a rotation state, the drive control unit 63 operates the movement mechanism 22 by the drive source to move the polishing tool in the first direction X1 by a distance corresponding to the amount of wear obtained from the wear pattern P. As a result, the linear abrasive material 2 is ejected in the first direction X1 by the amount of wear. In this example, the drive control unit 63 performs the abrasive material ejection operation when it detects the end of the rotation state.

[0064] The abrasive material length dimension calculation unit 64 calculates the abrasive material length dimension by subtracting the wear amount from the reference dimension M when the wear amount acquisition unit 62 first acquires the wear amount, and stores it in the storage unit 52. Subsequently, each time the wear amount acquisition unit 62 acquires the wear amount, the abrasive material length dimension calculation unit 64 calculates the new abrasive material length dimension by subtracting the wear amount from the abrasive material length dimension, and updates the abrasive material length dimension in the storage unit 52.

[0065] Each time the abrasive material length is calculated, the replacement determination unit 65 determines whether or not the polishing brush 3 needs to be replaced based on the abrasive material length and the reference dimension M. For example, the replacement determination unit 65 determines that the polishing brush 3 needs to be replaced if the value obtained by subtracting the abrasive material length from the reference dimension M becomes shorter than a predetermined threshold. When the replacement determination unit 65 determines that the polishing brush 3 needs to be replaced, the replacement notification unit 66 drives the light-emitting unit 54 to notify the user with light that the polishing brush 3 needs to be replaced.

[0066] The communication unit 55 communicates with the control unit 51 using a wireless network. The wireless network is defined by standards such as IEEE 802.11. The initial values ​​for the reference dimension M, wear pattern P, and number of polishing operations are input from the external device to the control unit 51 via the communication unit 55. The control unit 51 stores the input reference dimension M, wear pattern P, and number of polishing operations in the storage unit 52.

[0067] Here, the polishing tool holder 4 includes a power supply 59 that supplies power to the motor 35, control unit 51, rotation detector 53, and light-emitting unit 54, within the space inside the large-diameter portion 8. The power supply 59 is a battery. The battery is rechargeable from the outside by connecting a power cable. The polishing tool holder 4 includes a connector (not shown) for connecting the power supply 59 cable.

[0068] (Movement of the polishing tool holder during the polishing process) Figure 6 is a flowchart of the polishing process. Figure 7 is a flowchart of the operation of the polishing tool holder in the polishing process shown in Figure 6.

[0069] In manufacturing lines that produce goods, a polishing process is performed in which the same polishing operation is carried out on the same workpiece W multiple times in succession, while changing the workpiece W. The polishing tool 1 in this example is suitable for use in such a polishing process.

[0070] When performing such a polishing process using the polishing tool 1, as shown in Figure 4, the operator holds the polishing brush 3 (unused polishing brush 3) of standard dimension M in the polishing tool holder 4 (step ST1). Here, the memory unit 52 of the polishing tool holder 4 has the bristle length of the unused polishing brush 3 stored in advance as the standard dimension M. The memory unit 52 of the polishing tool holder 4 also has the number of polishing operations (0) stored in advance. Furthermore, the memory unit 52 of the polishing tool holder 4 has the amount of wear that occurs in one polishing operation, the number of polishing operations, and the associated wear pattern P (see Figure 4) for the linear abrasive material 2 (linear abrasive material 2 of the unused polishing brush 3) of standard dimension M stored in advance.

[0071] Next, the operator connects the shank of the polishing tool holder 4 to the spindle 5a of the machine tool 5 (step ST2). Then, the machine tool 5 positions the first workpiece W in the predetermined machining position (step ST3). The machine tool 5 then begins the polishing operation on the first workpiece W(1) (step ST4).

[0072] During the polishing operation, the machine tool 5 rotates the polishing tool 1, bringing it closer to the workpiece W(1), and sets the distance between the spindle 5a of the machine tool 5 and the polishing surface S of the workpiece W(1) to a set distance D. The set distance D is the distance at which the linear abrasive material 2 of the polishing brush 3, held in the polishing tool holder 4 connected to the spindle 5a, contacts the polishing surface S of the workpiece W(1) with a predetermined depth of cut E. The machine tool 5 also maintains the distance between the polishing tool holder 4 and the polishing surface S at the set distance D, and polishes the workpiece W(1) for a predetermined time while moving the polishing tool 1 along a predetermined polishing path along the polishing surface S.

[0073] Here, as shown in Figure 7, in step ST4, when the rotation detector 53 detects a rotation state, the control unit 51 of the polishing tool holder 4 calculates a new polishing operation count by adding 1 to the polishing operation count stored in the memory unit 52, and updates the polishing operation count in the memory unit 52 with the calculated polishing operation count (step ST21). Also, once the polishing operation count is calculated, the control unit 51 refers to the wear pattern P in the memory unit 52 based on the calculated polishing operation count to obtain the amount of wear (step ST22). Furthermore, once the amount of wear is obtained, the control unit 51 calculates the abrasive material length dimension by subtracting the amount of wear from the reference dimension M, and stores it in the memory unit 52 (step ST23).

[0074] Subsequently, as shown in Figure 6, once the polishing operation on the workpiece W(1) is complete, the machine tool 5 moves the polishing tool 1 away from the workpiece W(1) and stops the rotation of the polishing tool 1 (step ST5). The machine tool 5 also places the next workpiece W in the machining position in place of the first workpiece W(1) (step ST6).

[0075] Here, in step ST5, the control unit 51 of the polishing tool holder 4 detects that the rotation state of the polishing tool 1 has ended based on the output from the rotation detector 53, and performs an abrasive material ejection operation (step ST24). In the abrasive material ejection operation, the control unit 51 drives the motor 35 to move the polishing brush 3 in the first direction X1 by a distance corresponding to the amount of wear of the linear abrasive material 2 worn down by the polishing operation on the first workpiece W. As a result, the polishing tool holder 4 ejects the linear abrasive material 2 in the first direction X1. The control unit 51 also determines whether or not it is necessary to replace the polishing brush 3 based on the abrasive material length dimension and the reference dimension M stored in the memory unit 52 (step ST25). Since steps ST1 to ST5 are polishing operations on the first workpiece W1, the linear abrasive material 2 of the polishing brush 3 is sufficiently long at the time of step ST25. Therefore, in step ST25, it is determined that it is not necessary to replace the polishing brush 3.

[0076] Subsequently, as shown in Figure 6, the machine tool 5 begins the polishing operation of the next workpiece W(n) placed at the machining position (step ST7). That is, the machine tool 5 rotates the polishing tool 1 and brings it closer to the workpiece W(n) so that the distance between the spindle 5a and the workpiece W(n) is set to the specified distance D. As a result, the linear abrasive material 2 of the polishing brush 3 comes into contact with the polishing surface S of the workpiece W(n) with a predetermined depth of cut E. The machine tool 5 also maintains the distance between the polishing tool holder 4 and the polishing surface S at the specified distance D and moves the polishing tool 1 along a predetermined polishing path along the polishing surface S, performing polishing for a predetermined time.

[0077] Here, as shown in Figure 7, when the rotation detector 53 detects a rotation state in step ST7, the control unit 51 of the polishing tool holder 4 calculates a new polishing operation count by adding 1 to the polishing operation count stored in the memory unit 52, and updates the polishing operation count in the memory unit 52 (step ST31). Furthermore, once the polishing operation count is calculated, the control unit 51 refers to the wear pattern P based on the calculated polishing operation count to obtain the amount of wear (step ST32). In addition, once the amount of wear is obtained, the control unit 51 subtracts the amount of wear from the abrasive material length dimension stored in the memory unit 52 to calculate a new abrasive material length dimension, and updates the abrasive material length dimension in the memory unit 52 (step ST33).

[0078] Subsequently, once the polishing operation on the workpiece W(n) is complete, the machine tool 5 moves the polishing tool 1 away from the workpiece W(n) and stops the rotation of the polishing tool 1, as shown in Figure 6 (step ST8).

[0079] At this point, the machine tool 5 determines whether or not there is a workpiece to be polished (step ST9). If there is a workpiece to be polished (Step ST9: Yes), the machine tool 5 places the next workpiece W in place of the current workpiece W(n) at the machining position (Step ST10). If there is no workpiece to be polished (Step ST9: No), the polishing process ends.

[0080] Here, as shown in Figure 7, when the control unit 51 of the polishing tool holder 4 detects in step ST8 that the rotation state of the polishing tool 1 has ended based on the output from the rotation detector 53, it performs an abrasive material ejection operation (step ST34). In the abrasive material ejection operation, the control unit 51 moves the polishing brush 3 in the first direction X1 by a distance corresponding to the amount of wear of the linear abrasive material 2 worn by the polishing operation on the workpiece W. As a result, the polishing tool holder 4 ejects the linear abrasive material 2 in the first direction X1. The control unit 51 also determines whether or not the polishing brush 3 needs to be replaced based on the abrasive material length dimension and the reference dimension M stored in the memory unit 52 (step ST35). If the control unit 51 determines that the polishing brush 3 needs to be replaced, it drives the light-emitting unit 54 to notify that the polishing brush 3 needs to be replaced by light (step ST36). When the light-emitting unit 54 lights up, the operator stops the machine tool 5 and replaces the polishing brush 3.

[0081] Subsequently, the machine tool 5 performs a polishing operation on the next workpiece W placed at the machining position, as shown in Figure 6 (steps ST7 and ST8). Then, in the polishing process, steps ST8 to ST11 are repeated until there are no more workpieces W to be polished (step ST9).

[0082] If the light-emitting unit 54 indicates that the polishing brush 3 needs to be replaced (step ST36), the operator stops the machine tool 5 and replaces the polishing brush 3 with a new one. After that, the next workpiece W to be polished is treated as the first workpiece W, and steps ST7 to ST10 are repeated until there are no more workpieces W to be polished.

[0083] (Effects and Benefits) In this example, the polishing tool holder 4 includes a moving mechanism 22 for moving the polishing brush 3 supported by a support mechanism 21, a control unit 51 for driving and controlling the motor 35 which is the drive source for the moving mechanism 22, and a power supply 59 for supplying power to the motor 35 and the control unit 51. Therefore, the polishing tool holder 4 can move the polishing brush 3 in the axial direction X by driving the moving mechanism 22 through the drive control of the motor 35 by the control unit 51. Thus, the polishing tool holder 4 can automatically perform an abrasive material ejection operation in which the linear abrasive material 2 is ejected in the first direction X1 by moving the polishing brush 3 in the axial direction X.

[0084] Furthermore, the memory unit 52 of the polishing tool holder 4 stores the reference dimension M, which is the dimension of the linear abrasive material 2 when the polishing brush 3 is supported by the support mechanism 21; the number of polishing operations, which is the number of times the rotation detector 53 has detected a rotation state; and the wear pattern P, which is associated with the amount of wear and the number of polishing operations when the linear abrasive material 2 of reference dimension M is polished on the workpiece W in one polishing operation. When the rotation detector 53 detects a rotation state, the control unit 51 adds 1 to the number of polishing operations to update the number of polishing operations, and obtains the amount of wear by referring to the wear pattern P based on the updated number of polishing operations. Then, when the control unit 51 detects that the rotation state of the polishing tool 1 has ended based on the output from the rotation detector 53, it drives the motor 35 to operate the moving mechanism 22 and moves the polishing brush 3 in the axial direction X by a distance corresponding to the amount of wear, performing an abrasive material ejection operation to eject the linear abrasive material 2.

[0085] Here, if the abrasive material of the polishing tool mounted in the polishing tool holder 4 is a linear abrasive material 2, even when performing the same polishing operation to polish parts of the same shape, the amount of wear of the linear abrasive material 2 in one polishing operation will differ depending on the length dimension of the linear abrasive material 2 at the start of the polishing operation. In other words, if the abrasive material is a linear abrasive material 2, the shorter the length dimension of the linear abrasive material 2 at the start of the polishing operation, the greater the rigidity of the linear abrasive material 2, and therefore the greater the amount of wear in one polishing operation. Consequently, if the amount of protrusion of the linear abrasive material 2 (the amount of movement of the polishing brush 3) by the abrasive material protrusion operation is kept constant, the amount of cutting E of the linear abrasive material 2 for the next workpiece W will change, which leads to a problem of variation in the accuracy of the polishing process among multiple workpieces W that are polished continuously.

[0086] In contrast, the polishing tool holder 4 obtains the amount of wear of the linear abrasive material 2 from the wear pattern P stored in the memory unit 52 after each polishing operation is completed. The wear pattern P is a combination of the amount of wear that occurs in one polishing operation and the number of polishing operations for the linear abrasive material 2 of reference dimension M at the time the polishing brush 3 is supported by the support mechanism 21. The wear pattern P also takes into account the change in the amount of wear due to the length of the bristles of the linear abrasive material 2. Therefore, if the amount of wear is obtained by referring to the wear pattern P based on the number of polishing operations, the obtained amount of wear will reflect the amount of wear of the linear abrasive material 2 that changes depending on the length dimension of the linear abrasive material 2 at the start of the polishing operation. Thus, in the polishing tool holder 4 of this example, the amount of protrusion of the linear abrasive material 2 due to the abrasive material protrusion operation can be made to correspond to the amount of wear of the linear abrasive material 2 due to the polishing of the previous workpiece W. Therefore, by holding the polishing brush 3 in the polishing tool holder 4, the linear abrasive material 2 can be automatically extended in a polishing process in which the same polishing operation is performed multiple times in succession while changing the workpiece W, and variations in the polishing accuracy for each workpiece W can be prevented or suppressed.

[0087] The polishing tool holder 4 also includes a light-emitting unit 54. The control unit 51 includes an abrasive material length dimension calculation unit 64 that, when the amount of wear is first acquired, calculates the dimension obtained by subtracting the amount of wear from the reference dimension M as the abrasive material length dimension and stores it in the storage unit 52, and thereafter, each time the amount of wear is acquired, calculates the dimension obtained by subtracting the amount of wear from the abrasive material length dimension as the new abrasive material length dimension and updates the abrasive material length dimension in the storage unit 52, and a replacement determination unit 65 that, each time the abrasive material length dimension is calculated, determines whether or not the polishing brush 3 needs to be replaced based on the abrasive material length dimension and the reference dimension M. If the replacement determination unit 65 determines that the polishing brush 3 needs to be replaced, it drives the light-emitting unit 54 to notify that the polishing brush 3 needs to be replaced. In other words, each time the polishing operation is completed, the control unit 51 calculates the abrasive material length dimension of the linear abrasive material 2 at the end of the operation and determines whether or not replacement is necessary based on the abrasive material length dimension and the reference dimension M. Then, if the control unit 51 determines that replacement is necessary, it drives the light-emitting unit 54 to notify that the polishing brush 3 needs to be replaced. Therefore, the polishing tool holder 4 makes it easy for the operator to recognize when it is time to replace the polishing brush 3.

[0088] Note that the wear pattern P of the linear abrasive material 2 shown in Figure 5 is just one example. Therefore, the wear pattern P stored in the memory unit 52 is not limited to this. In other words, the wear pattern P will differ depending on the material of the linear abrasive material 2.

[0089] (modified version) The rotation detector 53 can be a vibration sensor. When the polishing tool holder 4 is rotated by the machine tool 5, vibrations are generated in the polishing tool holder 4. Therefore, the rotation state of the polishing tool holder 4 can be detected by the vibration sensor that detects these vibrations.

[0090] Furthermore, the rotation detector 53 includes a conductive member that moves due to centrifugal force, and the conductive member can act as a switch that interrupts the circuit. In other words, when centrifugal force is generated, the conductive member moves to the outer circumference and contacts the contacts of the circuit, so that the circuit becomes conductive, and the rotation detector 53 can be a switch that does this.

[0091] Furthermore, instead of the light-emitting unit 54, a sounding unit equipped with a buzzer or the like may be provided as a notification unit to notify that the polishing brush 3 needs to be replaced. In this case, when the replacement determination unit 65 determines that the polishing brush 3 needs to be replaced, it drives the sounding unit to notify that the polishing brush 3 needs to be replaced by sound.

[0092] Furthermore, the battery of the power supply 59 can be wirelessly rechargeable. In addition, the power supply 59 may be detachable from the polishing tool holder 4 and replaceable. Power may be supplied to the motor 35 and the control unit 51 from a single battery, or two batteries may be provided, one for powering the motor 35 and the other for powering the control unit 51.

[0093] Furthermore, the communication unit 55 may communicate with external devices and the control unit 51 via infrared communication, Bluetooth®, or the like. Alternatively, the communication unit 55 may be equipped with a connector to which a communication cable can be detachably connected, and may communicate with external devices and the control unit 51 via wired communication.

[0094] Alternatively, a direct drive mechanism can be employed in which the motor 35 directly drives the shaft member 36. In this case, the drive force transmission mechanism 44 is a connecting member that connects the output shaft of the motor 35 to the shaft member 36.

[0095] (Example 2) Figure 8 is an external perspective view of the polishing tool of Embodiment 2 to which the present invention is applied. Figure 9 is a perspective view of the polishing tool included in the polishing tool of Embodiment 2. Figure 10 is an explanatory diagram of the wear pattern stored by the polishing tool holder in the polishing tool of Embodiment 2. As shown in Figures 8 and 9, the polishing tool 70 of the polishing tool 1A of Embodiment 2 is equipped with an elastic grinding wheel 71 as the abrasive material. Since the polishing tool 1A has the same configuration as the polishing tool 1A of Embodiment 1, the same reference numerals are used for opposing components, and their descriptions are omitted.

[0096] As shown in Figure 8, the polishing tool 1A includes a polishing tool 70 and a polishing tool holder 4 that detachably holds the polishing tool 70. As shown in Figure 9, the polishing tool 70 includes an abrasive material holder 11 and an elastic grinding wheel 71 held in the abrasive material holder 11. The polishing tool holder 4 is the same as the polishing tool holder 4 of the polishing tool 1A of Embodiment 1, but the wear pattern P1 stored in the memory unit 52 is different from the wear pattern P of the polishing tool 1A of Embodiment 1.

[0097] (polishing tool) As shown in Figure 8, the abrasive tool 70 includes a cylindrical elastic grinding wheel 71 extending in the axial direction X as an abrasive material. The abrasive material holder 11 holds one end of the elastic grinding wheel 71 in the axial direction X. The elastic grinding wheel 71 contains an elastic foam, a polymer, and abrasive grains. In this example, the elastic foam is a melamine resin foam. In this example, the elastic foam is an anisotropic elastic foam in which anisotropy is imparted to the elastic force by compression in one direction.

[0098] The base material of the elastic grinding wheel 71 is obtained by impregnating an anisotropic elastic foam with a dispersion containing a polymer and abrasive grains, and then firing it. In anisotropic elastic foam, the direction in which the elastic force is strongest is the compression direction. The elastic grinding wheel 71 is formed such that when the grinding tool 70 is held in the grinding tool holder 4, the compression direction of the anisotropic elastic foam coincides with the axial direction X.

[0099] The polymer functions as a binder. The polymer is one of the following: epoxy resin, urethane resin, polyester resin, or polyrotaxane. In this example, the polymer is polyrotaxane. The abrasive grain is appropriately selected depending on the type of workpiece W. As abrasive grains, diamond, alumina, silica, silicon carbide, silicon nitride, boron carbide, titania, cerium oxide, or zirconia can be used. Alternatively, the abrasive material can be an organic material such as walnut or synthetic resin. In this example, the abrasive grain is alumina.

[0100] As shown in Figure 8, the abrasive holder 11 is an annular member having a holder through-hole 12 extending in the axial direction X. The abrasive holder 11 also has a single circular abrasive holding hole 13 on its front end face that surrounds the holder through-hole 12. The opening of the holder through-hole 12 in the first direction X1 opens at the center of the circular bottom surface of the abrasive holding hole 13. The end portion of the elastic grinding wheel 71 in the second direction X2 is inserted into the abrasive holding hole 13 and fixed to the abrasive holder 11 with adhesive. The abrasive holder 11 also has a recess on its rear end face. The recess is coaxial with the holder through-hole 12 and has a larger inner diameter than the holder through-hole 12. The recess is a connecting portion 15 for holding the polishing tool 70 in the polishing tool holder 4.

[0101] The polishing tool 70 is connected to the connecting member 24 with its connecting portion 15 fitted into the projection 26 of the connecting member 24. When the polishing tool 70 is connected to the connecting member 24, the through hole 28 of the connecting member 24 and the holder through hole 12 are in communication. When the polishing brush 3 is connected to the connecting member 24, the polishing brush 3 and the connecting member 24 become one unit. Here, the connecting member 24 is supported on the shaft member 36 with its female thread 29 screwed into the male thread 36a of the shaft member. As a result, the polishing tool 70 is supported by the support mechanism 21 in a state where it can move in the axial direction X. Furthermore, the polishing tool 70 is supported by the support mechanism 21 with the abrasive holder 11 located inside the sleeve 7 and the end of the elastic grinding wheel 71 in the first direction X1 protruding from the sleeve 7.

[0102] Here, the memory unit 52 of the polishing tool holder 4 stores the reference dimension M, which is the dimension of the elastic grinding wheel 71 when the polishing tool 70 is supported by the support mechanism 21; the number of polishing operations, which is the number of times the rotation detector 53 has detected a rotation state; and a wear pattern P1, which associates the amount of wear that occurs in one polishing operation with the number of polishing operations for an elastic grinding wheel 71 of reference dimension M (an unused elastic grinding wheel 71). Figure 10 shows the wear pattern P1 of the elastic grinding wheel 71. According to the wear pattern P1 of the elastic grinding wheel 71, as the dimension of the elastic grinding wheel 71 decreases (as the number of polishing operations increases), the amount of wear that occurs in one polishing operation increases linearly.

[0103] The polishing tool 1A in this example can achieve the same effects as the polishing tool 1 in Example 1. Specifically, with the polishing tool 1A, in a polishing process in which the same polishing operation is performed multiple times in succession while changing the workpiece W, the protrusion of the elastic grinding wheel 71 can be automatically controlled, and the amount of protrusion of the elastic grinding wheel 71 can be adjusted to correspond to the amount of wear on the elastic grinding wheel 71 caused by the polishing operation of the previous workpiece W. Therefore, variations in the polishing accuracy for each workpiece W can be prevented or suppressed. Furthermore, with the polishing tool 1A in this example, the polishing tool 70 can be replaced at an appropriate timing.

[0104] (Example 3) Figure 11 is a perspective view of the polishing tool of Example 3. The polishing tool 80 of polishing tool 1B in this example is the same as that of polishing tool 70 in Example 2, but with the elastic grinding wheel 71 replaced by a rigid grinding wheel 81. In other words, the configuration of polishing tool 80 is the same as that of polishing tool 70, except for the abrasive material.

[0105] As shown in Figure 9, the polishing tool 1B includes a polishing tool 80 and a polishing tool holder 4 that detachably holds the polishing tool 80. The polishing tool 80 comprises an abrasive material holder 11 and a rigid grinding wheel 81 held in the abrasive material holder 11. The grinding wheel 81 is made of abrasive grains solidified with a binder such as vitrified material, or it is a natural grinding wheel. The grinding wheel 81 has a cylindrical shape extending in the axial direction X.

[0106] In polishing tool 1B, the polishing tool holder 4 is identical to that of polishing tool 1 in Example 1 and polishing tool 1A in Example 2, except for the wear pattern P2 stored in the memory unit 52. Therefore, in polishing tool 1B, the same reference numerals are used for components corresponding to polishing tools 1 and 1A, and their descriptions are omitted.

[0107] The memory unit 52 of the polishing tool holder 4 stores the reference dimension M, which is the dimension of the grinding wheel 81 when the polishing tool 80 is supported by the support mechanism 21; the number of polishing operations, which is the number of times the rotation detector 53 has detected a rotation state; and a wear pattern P2 that associates the amount of wear that occurs in one polishing operation with the number of polishing operations for a grinding wheel 81 of reference dimension M (an unused grinding wheel 81). Figure 12 shows the wear pattern P2 of the grinding wheel 81. According to the wear pattern P2 of the grinding wheel 81, the amount of wear that occurs in one polishing operation is constant, regardless of the dimension of the grinding wheel 81 at the start of the polishing operation (regardless of the number of polishing operations).

[0108] The polishing tool 1B in this example can achieve the same effects as the polishing tool 1A in Example 1. Specifically, with the polishing tool 1A, in a polishing process in which the same polishing operation is performed multiple times in succession while changing the workpiece W, the protrusion of the grinding wheel 81 is automatically controlled, and the amount of protrusion of the grinding wheel 81 can be adjusted to correspond to the amount of wear on the grinding wheel 81 caused by the polishing operation of the previous workpiece W. Therefore, variations in the polishing accuracy for each workpiece W can be prevented or suppressed. Furthermore, with the polishing tool 1B in this example, the polishing tool 80 can be replaced at an appropriate timing.

[0109] (Polishing system) Next, the polishing system of this example will be described with reference to Figure 13. As shown in Figure 13, the polishing system 100 of this example comprises a polishing tool 101 and a cloud computer 103 that is communicably connected to the polishing tool 101 via a network 102. The polishing tool 101 has a polishing tool and a polishing tool holder 4 that holds the polishing tool. In this example, the polishing tool is a polishing brush 3. Therefore, the abrasive material provided by the polishing tool is a linear abrasive material 2. Note that the polishing tool 101 has the same configuration as the polishing tool 1 of Example 1. Therefore, the same reference numerals are used for the corresponding components, and their detailed descriptions are omitted.

[0110] (Polishing brush) The polishing brush 3 is shown in Figure 2. As shown in Figure 13, the abrasive material holder 11 of the polishing brush 3 is an annular member and has a holder through hole 12 extending in the axial direction X. The abrasive material holder 11 also has a plurality of abrasive material holding holes 13 on its end face 11a in the first direction X1. Multiple linear abrasive materials 2 are divided into smaller bundles and bundled together. The rear end of the bundled abrasive material bundle 14 is inserted into the abrasive material holding hole 13 and fixed to the abrasive material holder 11 with adhesive. The abrasive material holder 11 also has a recess on its rear end face. The recess is a connecting part 15 for holding the polishing brush 3 in the polishing tool holder 4.

[0111] The polishing tool holder 4 has a shank 6 connected to the spindle 5a of the machine tool 5. The polishing tool holder 4 also has a support mechanism 21 that supports the polishing brush 3 so that it can move along the axial direction X of the shank 6, and a moving mechanism 22 that moves the polishing brush 3 along the axial direction X, and a motor 35 (drive source). Furthermore, the polishing tool holder 4 is equipped with a light-emitting unit 54 (notification unit). The polishing tool holder 4 also has a control unit 51, a rotation detector 53 that detects the rotational state being rotated by the machine tool 5, and a power supply 59 that supplies power to the motor 35 and the control unit 51. These configurations are the same as those of the polishing tool holder 4 of the polishing tool 1 of Embodiment 1.

[0112] Furthermore, the polishing tool holder 4 includes a control unit 51 and a communication unit 55 connected to the control unit 51. The control unit 51 drives the motor 35 based on a drive command. The control unit 51 also drives the light-emitting unit 54 based on a notification command. The communication unit 55 communicates with the cloud computer 103 via the network 102. The communication unit 55 transmits the output from the rotation detector 53 to the cloud computer 103 and receives drive commands and notification commands from the cloud computer 103 and inputs them to the control unit 51.

[0113] In this example, the control unit 51 does not include a polishing operation count update unit 61 and a wear amount acquisition unit 62. Furthermore, the control unit 51 does not include abrasive material length dimension calculation unit 64 and a replacement determination unit 65. Additionally, the polishing tool holder 4 does not include a storage unit 52.

[0114] Meanwhile, the cloud computer 103 includes a storage unit 52. The storage unit 52 stores a reference dimension M, which is the dimension of the abrasive material when the polishing brush 3 is supported by the support mechanism 21 of the polishing tool holder 4; the number of polishing operations, which is the number of times the rotation detector 53 has detected a rotation state; and a wear pattern P, which is associated with the amount of wear and the number of polishing operations when the abrasive material of reference dimension M is polished on a workpiece in one polishing operation. The initial values ​​of the reference dimension M, the wear pattern P, and the number of polishing operations are input to the cloud computer 103 from an external device via the network 102 and stored in the storage unit 52.

[0115] Furthermore, the cloud computer 103 includes a cloud computer-side control unit 104 and a cloud computer-side communication unit 105 connected to the cloud computer-side control unit 104. The cloud computer-side control unit 104 is communicatively connected to the storage unit 52. The cloud computer-side communication unit 105 communicates with external devices via the network 102. The cloud computer-side communication unit 105 enables communication between external devices and the cloud computer-side control unit 104.

[0116] The cloud computer-side control unit 104 includes a polishing tool control unit 106. The polishing tool control unit 106 includes a polishing operation count update unit 61 and a wear amount acquisition unit 62. The polishing operation count update unit 61 monitors the output from the rotation detector 53 of the polishing tool holder 4, and when the rotation detector 53 detects a rotation state, it calculates a new polishing operation count by adding 1 to the polishing operation count and updates the polishing operation count in the storage unit 52. When the polishing operation count is calculated, the wear amount acquisition unit 62 obtains the wear amount by referring to the wear pattern P in the storage unit 52 based on the polishing operation count.

[0117] The polishing tool control unit 106 also includes a drive command issuing unit 107 and a command transmitting unit 108. The drive command issuing unit 107 monitors the output from the rotation detector 53 of the polishing tool holder 4, and issues a drive command when it detects that the rotation state has ended based on the output from the rotation detector 53. The drive command is a command to drive the motor 35 of the polishing tool 101 to operate the moving mechanism 22 and perform an abrasive material ejection operation, moving the polishing brush 3 to the opposite side of the shank 6 by a distance corresponding to the amount of wear. When a drive command is issued, the command transmitting unit 108 transmits the drive command to the polishing tool holder 4. In this example, the drive command issuing unit 107 issues a drive command when it detects the end of the rotation state based on the output from the rotation detector 53. Also, when a drive command is issued, the command transmitting unit 108 transmits the drive command to the polishing tool 1 without delay.

[0118] Furthermore, the polishing tool control unit 106 includes an abrasive material length dimension calculation unit 64 and a replacement determination unit 65. When the amount of wear is first acquired, the abrasive material length dimension 64 calculates the dimension obtained by subtracting the amount of wear from the reference dimension M as the abrasive material length dimension and stores it in the storage unit 52. Thereafter, each time the amount of wear is acquired, it calculates the dimension obtained by subtracting the amount of wear from the abrasive material length dimension as the new abrasive material length dimension and updates the abrasive material length dimension in the storage unit 52. Each time the abrasive material length dimension is calculated, the replacement determination unit 65 determines whether or not the polishing brush 3 needs to be replaced based on the abrasive material length dimension and the reference dimension M.

[0119] Furthermore, the polishing tool control unit 106 includes a notification command issuing unit 109. The notification command issuing unit 109 issues a notification command when the replacement determination unit 65 determines that the polishing brush 3 needs to be replaced. The notification command is a command to drive the light-emitting unit 54. When a notification command is issued, the command transmission unit 108 transmits the notification command to the polishing tool holder 4.

[0120] (Operation of the polishing system in the polishing process) Figure 14 is a flowchart of the operation of the polishing tool 1 and the cloud computer 103 in the polishing process shown in Figure 6. The flowchart of the polishing process when using the polishing system 100 is the same as the flowchart of the polishing process shown in Figure 6. In the polishing system 100, the polishing tool 1 (polishing tool holder 4) transmits the output from the rotation detector 53 to the cloud computer 103. The polishing tool control unit 106 of the cloud computer 103 monitors the output from the rotation detector 53.

[0121] When performing the polishing process, as shown in Figure 6, the operator holds a polishing brush 3 (an unused polishing brush 3) of standard dimension M in the polishing tool holder 4 (step ST1). Here, the storage unit 52 of the cloud computer 103 has in advance stored the value of the bristle length of the unused polishing brush 3 as the standard dimension M. The storage unit 52 of the cloud computer 103 also has in advance stored the number of polishing operations (0). Furthermore, the storage unit 52 of the cloud computer 103 has in advance stored the amount of wear that occurs in one polishing operation, the number of polishing operations, and the associated wear pattern P (see Figure 4) for the linear abrasive material 2 (the linear abrasive material 2 of the unused polishing brush 3) of standard dimension M.

[0122] Next, the operator connects the shank of the polishing tool holder 4 to the spindle 5a of the machine tool 5 (step ST2). Then, the machine tool 5 positions the first workpiece W in the predetermined machining position (step ST3). The machine tool 5 then begins the polishing operation on the first workpiece W(1) (step ST4).

[0123] During the polishing operation, the machine tool 5 rotates the polishing tool 1, bringing it closer to the workpiece W(1), and sets the distance between the spindle 5a of the machine tool 5 and the polishing surface S of the workpiece W(1) to a set distance D. The set distance D is the distance at which the linear abrasive material 2 of the polishing brush 3, held in the polishing tool holder 4 connected to the spindle 5a, contacts the polishing surface S of the workpiece W(1) with a predetermined depth of cut E. The machine tool 5 also maintains the distance between the polishing tool holder 4 and the polishing surface S at the set distance D, and polishes the workpiece W(1) for a predetermined time while moving the polishing tool 1 along a predetermined polishing path along the polishing surface S.

[0124] In step ST4, the polishing tool control unit 106 detects the rotation state of the polishing tool 1 based on the output from the rotation detector 53. As shown in Figure 14, upon detecting the rotation state of the polishing tool 1, the polishing tool control unit 106 calculates a new polishing operation count by adding 1 to the polishing operation count stored in the memory unit 52, and updates the polishing operation count in the memory unit 52 with the calculated polishing operation count (step ST41). Furthermore, once the polishing operation count is calculated, the polishing tool control unit 106 obtains the amount of wear by referring to the wear pattern P in the memory unit 52 based on the calculated polishing operation count (step ST42). In addition, once the amount of wear is obtained, the polishing tool control unit 106 calculates the abrasive material length dimension by subtracting the amount of wear from the reference dimension M, and stores it in the memory unit 52 (step ST43).

[0125] Subsequently, as shown in Figure 6, once the polishing operation on the workpiece W(1) is complete, the machine tool 5 moves the polishing tool 1 away from the workpiece W(1) and stops the rotation of the polishing tool 1 (step ST5). The machine tool 5 also places the next workpiece W in the machining position in place of the first workpiece W(1) (step ST6).

[0126] Here, in step ST5, the polishing tool control unit 106 detects that the rotation state of the polishing tool 1 has ended based on the output from the rotation detector 53. As shown in Figure 14, when the polishing tool control unit 106 detects that the rotation state of the polishing tool 1 has ended, it issues a drive command and transmits it to the polishing tool 1. The drive command is a command to drive the motor 35 of the polishing tool holder 4 to move the polishing brush 3 in the first direction X1 by a distance corresponding to the amount of wear of the linear abrasive material 2 worn down by the polishing operation on the first workpiece W (step ST44). The polishing tool control unit 106 also determines whether or not it is necessary to replace the polishing brush 3 based on the abrasive material length dimension and the reference dimension M stored in the memory unit 52 (step ST45). Note that from steps ST1 to ST5, it is a polishing operation on the first workpiece W1, so at step ST45, the linear abrasive material 2 of the polishing brush 3 is sufficiently long. Therefore, in step ST25, it is determined that it is not necessary to replace the polishing brush 3.

[0127] Here, the polishing tool 1, having received the drive command, performs an abrasive material ejection operation (step ST46). In the abrasive material ejection operation, the polishing tool control unit 106 drives the motor 35 to move the polishing brush 3 in the first direction X1 by a distance corresponding to the amount of wear of the linear abrasive material 2 worn down by the polishing operation on the first workpiece W. As a result, the polishing tool control unit 106 ejects the linear abrasive material 2 in the first direction X1.

[0128] Subsequently, as shown in Figure 6, the machine tool 5 starts the polishing operation of the next workpiece W(n) placed at the machining position (step ST7). That is, the machine tool 5 rotates the polishing tool 1 and brings it closer to the workpiece W(n) so that the distance between the spindle 5a and the workpiece W(n) is set to distance D. As a result, the linear abrasive material 2 of the polishing brush 3 comes into contact with the polishing surface S of the workpiece W(n) with a predetermined depth of cut E. The machine tool 5 also maintains the distance between the polishing tool control unit 106 and the polishing surface S at distance D, and moves the polishing tool 1 along a predetermined polishing path along the polishing surface S, performing polishing for a predetermined time.

[0129] In step ST7, the polishing tool control unit 106 detects the rotation state of the polishing tool 1 based on the output from the rotation detector 53. As shown in Figure 14, upon detecting the rotation state of the polishing tool 1, the polishing tool control unit 106 calculates a new polishing operation count by adding 1 to the polishing operation count stored in the memory unit 52, and updates the polishing operation count in the memory unit 52 (step ST51). Furthermore, once the polishing operation count is calculated, the polishing tool control unit 106 obtains the amount of wear by referring to the wear pattern P based on the calculated polishing operation count (step ST52). In addition, once the amount of wear is obtained, the polishing tool control unit 106 calculates a new abrasive material length by subtracting the amount of wear from the abrasive material length stored in the memory unit 52, and updates the abrasive material length in the memory unit 52 (step ST53).

[0130] Subsequently, once the polishing operation on the workpiece W(n) is complete, the machine tool 5 moves the polishing tool 1 away from the workpiece W(n) and stops the rotation of the polishing tool 1, as shown in Figure 6 (step ST8).

[0131] At this point, the machine tool 5 determines whether or not there is a workpiece to be polished (step ST9). If there is a workpiece to be polished (step ST9: Yes), the machine tool 5 places the next workpiece W in place of the current workpiece W(n) at the machining position (step ST10). If there is no workpiece to be polished (step ST9: No), the polishing process ends.

[0132] In step ST8, the polishing tool control unit 106 detects that the rotation state of the polishing tool 1 has ended based on the output from the rotation detector 53. As shown in Figure 14, upon detecting that the rotation state of the polishing tool 1 has ended, the polishing tool control unit 106 issues a drive command and transmits it to the polishing tool 1. The drive command is a command to drive the motor 35 of the polishing tool holder 4 to move the polishing brush 3 in the first direction X1 by a distance corresponding to the amount of wear of the linear abrasive material 2 worn by the polishing operation on the first workpiece W (step ST54). The polishing tool control unit 106 also determines whether or not the polishing brush 3 needs to be replaced based on the abrasive material length dimension and the reference dimension M stored in the memory unit 52 (step ST55). If the polishing tool control unit 106 determines that the polishing brush 3 needs to be replaced (step ST55: Yes), it issues a notification command and transmits it to the polishing tool 1 (step ST56).

[0133] Here, upon receiving the drive command in step ST54, the polishing tool 1 performs an abrasive material ejection operation (step ST57). In the abrasive material ejection operation, the polishing tool control unit 106 drives the motor 35 to move the polishing brush 3 in the first direction X1 by a distance corresponding to the amount of wear of the linear abrasive material 2 worn down by the initial polishing operation on the workpiece W. As a result, the polishing tool control unit 106 ejects the linear abrasive material 2 in the first direction X1. Also, upon receiving the notification command in step ST56, the polishing tool 1 drives the light-emitting unit 54 to notify with light that the polishing brush 3 needs to be replaced (step ST58). When the light-emitting unit 54 lights up, the operator stops the machine tool 5 and replaces the polishing brush 3.

[0134] Subsequently, the machine tool 5 performs a polishing operation on the next workpiece W placed at the machining position, as shown in Figure 6 (steps ST7 and ST8). Then, in the polishing process, steps ST8 to ST11 are repeated until there are no more workpieces W to be polished (step ST9).

[0135] If the light-emitting unit 54 indicates that the polishing brush 3 needs to be replaced (step ST58), the operator stops the machine tool 5 and replaces the polishing brush 3 with a new one. After that, the next workpiece W to be polished is treated as the first workpiece W, and steps ST7 to ST10 are repeated until there are no more workpieces W to be polished.

[0136] (Effects and Benefits) The polishing system 100 of the present invention comprises a polishing tool 1 consisting of a polishing tool holder 4 and a polishing brush 3, and a cloud computer 103 connected to the polishing tool 1 (polishing tool holder 4) via a network 102. The polishing tool control unit 106 of the cloud computer 103 includes a drive command issuing unit 107 that issues drive commands. The polishing tool holder 4 includes a motor 35 (drive source), a moving mechanism 22 that moves the polishing brush 3 supported by a support mechanism 21, a control unit 51 that drives and controls the motor 35 based on the drive command, and a power supply 59 that supplies power to the motor 35 and the control unit 51. Therefore, the polishing system 100 can drive the moving mechanism 22 of the polishing tool holder 4 based on the drive command from the cloud computer 103 to move the polishing brush 3 in the axial direction X. Thus, the polishing tool 101 can automatically perform an abrasive material ejection operation in which the linear abrasive material 2 is ejected on the opposite side from the shank 6 by moving the polishing brush 3 in the axial direction X.

[0137] In this example, the cloud computer 103, which can communicate with the polishing tool holder 4, obtains the amount of wear by referring to the wear pattern P stored in the storage unit 52 of the cloud computer 103 after each polishing operation is completed in the polishing tool 101. Furthermore, once the cloud computer 103 obtains the amount of wear, it issues a drive command to the polishing tool holder 4 to drive the motor 35 of the polishing tool 101 to operate the moving mechanism 22 and perform an abrasive material ejection operation, moving the polishing brush 3 to the opposite side of the shank by a distance corresponding to the amount of wear. Upon receiving the drive command, the polishing tool 101 drives the motor 35 to perform the abrasive material ejection operation. Here, the wear pattern P is a combination of the amount of wear that occurs in one polishing operation and the number of polishing operations for the linear abrasive material 2 of reference dimension M at the time it is supported by the support mechanism 21. Therefore, if the amount of wear is obtained by referring to the wear pattern P based on the number of polishing operations, the obtained amount of wear will reflect the amount of abrasive material wear that changes depending on the length dimension of the linear abrasive material 2 at the start of the polishing operation. Therefore, the amount of protrusion of the linear abrasive material 2 due to the abrasive material protrusion operation can be made to correspond to the amount of wear on the abrasive material due to the polishing of the previous workpiece W. Accordingly, with the polishing system 100, in a polishing process in which the same polishing operation is performed multiple times in succession while changing workpieces, the protrusion of the abrasive material can be performed automatically, and variations in the polishing accuracy for each workpiece can be prevented or suppressed.

[0138] Furthermore, when the drive command issuing unit 107 detects the end of the rotation state based on the output from the rotation detector 53, it may issue a drive command when the rotation detector 53 next detects a rotation state. In other words, after the polishing operation on one workpiece W is completed, when the machine tool 5 rotates the polishing brush 3 for the polishing operation on the next workpiece W, the cloud computer 103 may issue and transmit a drive command to cause the polishing tool 101 to perform an abrasive material ejection operation.

[0139] Here, the rotation detector 53 can be a vibration sensor. Furthermore, the rotation detector 53 may include a conductive member that moves due to centrifugal force, and this conductive member may act as a switch that interrupts the circuit.

[0140] In this example as well, the polishing tool holder 4 may hold a polishing tool 70 equipped with an elastic grinding wheel 71 as the abrasive material. Alternatively, the polishing tool holder 4 may hold a polishing tool 80 equipped with a rigid grinding wheel 81 as the abrasive material.

[0141] (Other embodiments) Here, the polishing system 100 may include a plurality of polishing tools 101 that are communicably connected to the cloud computer 103. Figure 15 is an explanatory diagram of the polishing system 100' which includes a plurality of polishing tools 101. Note that the polishing system 100' shown in Figure 15 has a configuration corresponding to the polishing system 100 described above, so the same reference numerals are used for opposing components and their descriptions are omitted.

[0142] The polishing system 100' in this example includes a first polishing tool 101A and a second polishing tool 101B, which are connected to a cloud computer 103 via a network 102 as polishing tools 101. The cloud computer 103 includes a cloud computer-side control unit 104, a storage unit 52, and a cloud computer-side communication unit 105. The cloud computer-side control unit 104 includes a polishing tool control unit 106, which includes a first polishing tool control unit 106A and a second polishing tool control unit 106B. The first polishing tool control unit 106A receives the output from the rotation detector 53 of the first polishing tool 101A. The first polishing tool control unit 106A also issues drive commands and notification commands and transmits them to the first polishing tool 101A. The second polishing tool control unit 106B receives the output from the rotation detector 53 of the second polishing tool 101B. Furthermore, the second grinding tool control unit 106B issues drive commands and notification commands and transmits them to the second grinding tool 101B. When acquiring the amount of wear, the first grinding tool control unit 106A and the second grinding tool control unit 106B each refer to the same wear pattern P stored in the storage unit 52.

[0143] The cloud computer 103 may identify the first polishing tool 101A and the second polishing tool 101B using individually assigned identification codes or the like. Alternatively, the cloud computer 103 may identify the first polishing tool 101A and the second polishing tool 101B using their respective addresses on the network 102.

[0144] In this example, in a manufacturing line performing a polishing process, the machine tools 5 include a first machine tool 5A and a second machine tool 5B that perform the same polishing process. A first polishing tool 101A is connected to the first machine tool 5A, and a second polishing tool 101B is connected to the second machine tool 5B. In such a case, using the polishing system 100', these multiple polishing tools 101 can be driven and controlled by a single cloud computer 103.

[0145] Furthermore, according to the polishing system 100', the amount of wear of the linear abrasive material 2 can be obtained based on a single wear pattern P stored in the memory unit 52 of the cloud computer 103, and the abrasive material ejection operation of multiple polishing tools 101 can be performed for each of them. Moreover, changes to the wear patterns P of multiple polishing tools 101 can be performed all at once by updating the wear patterns P in the memory unit 52.

[0146] Furthermore, according to this example, the cloud computer 103 can understand the wear status of the abrasive material of multiple polishing tools 101. Therefore, multiple polishing tools 101 connected to each machine tool can be centrally managed. In addition, the cloud computer 103 collects the outputs of the rotation detectors of the multiple polishing tools 101. Therefore, the cloud computer 103 can understand the operating status of each machine tool 5 based on the rotation status of each polishing tool 101.

[0147] Furthermore, if the first machine tool 5A and the second machine tool 5B perform different grinding processes, the first grinding tool 101A and the second grinding tool 101B may be equipped with different grinding tools. In this case, the first wear pattern and the second wear pattern are stored in the storage unit 52 of the cloud computer 103. The first grinding tool control unit 106A, which transmits a drive command to the first grinding tool 101A, can obtain the amount of wear by referring to the first wear pattern, and the second grinding tool control unit 106B, which transmits a drive command to the second grinding tool 101B, can obtain the amount of wear by referring to the second wear pattern.

Claims

1. A polishing tool holder comprising a shank connected to the spindle of a machine tool, an abrasive material holder, and an abrasive material held in the abrasive material holder, a support mechanism that supports the polishing tool so as to be movable in the axial direction of the shank, and a drive source and a moving mechanism that moves the polishing tool in the axial direction, The system comprises a control unit for controlling the drive source, a storage unit connected to the control unit, a rotation detector for detecting the rotational state of the machine tool, and a power supply for supplying power to the drive source and the control unit. The storage unit stores and retains a reference dimension, which is the dimension of the abrasive material at the time the polishing tool is supported by the support mechanism; the number of polishing operations, which is the number of times the rotation detector detects the rotation state; and a wear pattern associated with the amount of wear and the number of polishing operations when the abrasive material of the reference dimension is polished on a workpiece in one polishing operation. The polishing tool holder is characterized by comprising: a polishing operation count update unit that, when the rotation detector detects the rotation state, calculates a new polishing operation count by adding 1 to the polishing operation count and updates the polishing operation count in the storage unit; a wear amount acquisition unit that, when the polishing operation count is calculated, obtains the wear amount by referring to the wear pattern based on the polishing operation count; and a drive control unit that, when it detects that the rotation state has ended based on the output from the rotation detector, drives the drive source to operate the moving mechanism and performs an abrasive material ejection operation to move the polishing tool to the opposite side of the shank by a distance corresponding to the wear amount.

2. The polishing tool holder according to claim 1, characterized in that the drive control unit performs the abrasive material ejection operation when it detects the end of the rotation state.

3. The polishing tool holder according to claim 1, characterized in that when the drive control unit detects the end of the rotation state, it performs the abrasive material ejection operation when the rotation detector next detects the rotation state.

4. Equipped with a news department, The polishing tool holder according to claim 1, comprising: a control unit that, when the amount of wear is first acquired, calculates the abrasive material length dimension by subtracting the amount of wear from the reference dimension and stores it in the storage unit, and thereafter, each time the amount of wear is acquired, calculates the abrasive material length dimension by subtracting the amount of wear from the abrasive material length dimension as a new abrasive material length dimension and updates the abrasive material length dimension in the storage unit; a replacement determination unit that, each time the abrasive material length dimension is calculated, determines whether or not the polishing tool needs to be replaced based on the abrasive material length dimension and the reference dimension; and a replacement notification unit that, when it is determined that the polishing tool needs to be replaced, drives the notification unit to notify that the polishing tool needs to be replaced.

5. It is equipped with a communication unit that communicates with external devices, The polishing tool holder according to claim 1, characterized in that the reference dimensions and the wear pattern are input to the control unit via the communication unit and stored in the storage unit.

6. The polishing tool holder according to claim 1, characterized in that the rotation detector is an acceleration sensor.

7. The polishing tool holder according to claim 1, characterized in that the rotation detector is a vibration sensor.

8. The polishing tool holder according to claim 1, characterized in that the rotation detector comprises a conductive member that moves by centrifugal force, and the conductive member is a switch that interrupts the circuit.

9. The support mechanism comprises a connecting member having a through hole that penetrates in the axial direction, and a shaft member that is coaxial with the shank, penetrates the through hole, and extends in the axial direction. The aforementioned drive source is a motor, The moving mechanism comprises a rotation support mechanism that supports the shaft member so that it can rotate around the axis; a female screw provided on the inner circumferential surface of the through hole; a male screw provided on the outer circumferential surface of the shaft member that engages with the female screw; a drive force transmission mechanism that transmits the rotation of the motor to the shaft member; a sleeve that guides the connecting member in the axial direction on the outer circumferential side of the connecting member and the shaft member; and a rotation restricting mechanism that restricts the joint rotation of the connecting member and the shaft member. The abrasive tool is configured such that the abrasive holder is connected to the connecting member, and a portion of the abrasive material protrudes outward from the sleeve. The polishing tool holder according to claim 1, characterized in that the control unit drives the motor to rotate the shaft member and move the connecting member in the axial direction.

10. The polishing tool holder according to claim 1, The polishing tool comprises an abrasive material holder and an abrasive material held in the abrasive material holder, The abrasive material comprises a plurality of linear abrasive materials arranged in parallel with their longitudinal direction oriented toward the axial direction, The abrasive material holder holds one end of the plurality of linear abrasive materials in the axial direction, The polishing tool is supported by the polishing tool holder and is characterized by polishing the workpiece by bringing the other end of the plurality of linear abrasive materials into contact with the workpiece.

11. The polishing tool holder according to claim 1, The polishing tool comprises an abrasive material holder and an abrasive material held in the abrasive material holder, The abrasive material is an elastic grinding wheel, The abrasive holder holds one end of the elastic grinding wheel in the axial direction, The polishing tool is characterized by being supported by the polishing tool holder and polishing the workpiece by bringing the other end of the elastic grinding wheel into contact with the workpiece.

12. The polishing tool holder according to claim 1, The polishing tool comprises an abrasive material holder and an abrasive material held in the abrasive material holder, The abrasive material is a rigid grinding wheel, The abrasive holder holds one end of the grinding wheel in the axial direction, The polishing tool is characterized by being supported by the polishing tool holder and polishing the workpiece by bringing the other end of the grinding wheel into contact with the workpiece.

13. A polishing tool comprising an abrasive material holder and an abrasive material held in the abrasive material holder, a shank connected to the spindle of a machine tool, a support mechanism that supports the polishing tool so as to be movable in the axial direction of the shank, and a drive source, and a moving mechanism that moves the polishing tool in the axial direction, and a polishing system comprising a cloud computer that is communicably connected to the polishing tool holder via a network, The polishing tool holder comprises a control unit that controls the drive source based on a drive command, a rotation detector that detects the rotational state being rotated by the machine tool, a power supply that supplies power to the drive source and the control unit, and a communication unit that communicates with the cloud computer. The communication unit transmits the output from the rotation detector to the cloud computer and receives the drive command from the cloud computer and inputs it to the control unit. The cloud computer includes a storage unit that stores and holds a reference dimension which is the dimension of the abrasive material at the time the polishing tool is supported by the support mechanism, the number of polishing operations which is the number of times the rotation detector detects the rotation state, and a wear pattern which is associated with the amount of wear that occurs in one polishing operation when the abrasive material of the reference dimension polishes a workpiece and the number of polishing operations, and a polishing tool control unit. The polishing tool control unit comprises: a polishing operation count update unit that, when the rotation detector detects the rotation state, calculates a new polishing operation count by adding 1 to the polishing operation count and updates the polishing operation count in the storage unit; a wear amount acquisition unit that, when the polishing operation count is calculated, obtains the wear amount by referring to the wear pattern based on the polishing operation count; a drive command issuing unit that, when it detects that the rotation state has ended based on the output from the rotation detector, drives the drive source to operate the moving mechanism and issues a drive command to perform an abrasive material ejection operation that moves the polishing tool to the opposite side of the shank by a distance corresponding to the wear amount; and a command transmission unit that, when the drive command is issued, transmits the drive command to the polishing tool holder.

14. The polishing system according to claim 13, characterized in that the drive command issuing unit issues the drive command when it detects the end of the rotation state.

15. The polishing system according to claim 13, characterized in that when the drive command issuing unit detects the end of the rotation state, it issues the drive command when the rotation detector next detects the rotation state.

16. The polishing tool holder is equipped with a notification unit, The polishing tool control unit includes: an abrasive material length dimension calculation unit that, when the amount of wear is first acquired, calculates the dimension obtained by subtracting the amount of wear from the reference dimension as the abrasive material length dimension and stores it in the storage unit, and thereafter, each time the amount of wear is acquired, calculates the dimension obtained by subtracting the amount of wear from the abrasive material length dimension as a new abrasive material length dimension and updates the abrasive material length dimension in the storage unit; a replacement determination unit that, each time the abrasive material length dimension is calculated, determines whether or not the polishing tool needs to be replaced based on the abrasive material length dimension and the reference dimension; and a notification command issuing unit that, when it is determined that the polishing tool needs to be replaced, drives the notification unit to issue a notification command that the polishing tool needs to be replaced. The polishing system according to claim 13, characterized in that the command transmission unit transmits the notification command to the polishing tool holder when the notification command is issued.

17. The support mechanism comprises a connecting member having a through hole that penetrates in the axial direction, and a shaft member that is coaxial with the shank, penetrates the through hole, and extends in the axial direction. The aforementioned drive source is a motor, The moving mechanism comprises a rotation support mechanism that supports the shaft member so that it can rotate around the axis; a female screw provided on the inner circumferential surface of the through hole; a male screw provided on the outer circumferential surface of the shaft member that engages with the female screw; a drive force transmission mechanism that transmits the rotation of the motor to the shaft member; a sleeve that guides the connecting member in the axial direction on the outer circumferential side of the connecting member and the shaft member; and a rotation restricting mechanism that restricts the joint rotation of the connecting member and the shaft member. The abrasive tool is configured such that the abrasive holder is connected to the connecting member, and a portion of the abrasive material protrudes outward from the sleeve. The polishing system according to claim 13, characterized in that the control unit drives the motor to rotate the shaft member and move the connecting member in the axial direction.

18. The polishing tools include a first polishing tool and a second polishing tool that are connected to the cloud computer via a network in a manner that enables communication. The polishing system according to claim 13, wherein the cloud computer comprises, as the polishing tool control unit, a first polishing tool control unit that receives the output from the rotation detector of the first polishing tool and transmits the drive command to the first polishing tool, and a second polishing tool control unit that receives the output from the rotation detector of the second polishing tool and transmits the drive command to the second polishing tool.

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