Multi-tasking machine for gear machining
The multi-tasking machine automates the phase detection of workpiece and tool using a movable sensor unit, reducing costs and errors by integrating phase detection into a single system.
Patent Information
- Authority / Receiving Office
- JP · JP
- Patent Type
- Patents
- Current Assignee / Owner
- NACHI FUJIKOSHI CORP
- Filing Date
- 2022-05-20
- Publication Date
- 2026-07-01
AI Technical Summary
Existing gear machining technologies require separate acquisition of tool phase data, leading to increased manufacturing costs and potential mounting errors due to manual work.
A multi-tasking machine with a fixed bed, work spindle, tool spindle, phase detection device, and control unit, utilizing a movable sensor unit with a laser displacement sensor and rotation unit to simultaneously detect the phase of both the workpiece and tool, minimizing additional components and manual work.
Enables accurate phase adjustment of both workpiece and tool while reducing equipment costs and eliminating mounting errors through automated phase detection.
Smart Images
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Abstract
Description
Technical Field
[0001] The present invention relates to a composite machine tool that detects the phases of a workpiece and a tool using a sensor unit.
Background Art
[0002] In recent years, a composite machine tool that integrates a device capable of turning, such as a NC lathe, and a device capable of skiving has been put into practical use. When creating a high-hardness gear after heat treatment in such a composite machine tool, rough machining of the workpiece, finish machining of heat treatment distortion after heat treatment, and shaving are performed. Therefore, it is necessary to align the positions of the workpiece tooth groove and the tool blade groove (cutter blade groove), that is, to align the phases of the tool (cutter) and the workpiece.
[0003] Strictly speaking, it is not a composite machine tool, but for example, Patent Document 1 discloses a "gear processing machine that creates a gear by hobbing." The gear processing machine of Patent Document 1 includes "a laser displacement sensor having a light projecting unit that irradiates a linear laser beam substantially perpendicular to the rotation axis of the gear to the gear and a light receiving unit that receives the reflected light from the tooth surface of the gear, a sensor rotating unit that rotates the laser displacement sensor, means for measuring the distance from the gear to the light projecting unit by the light receiving unit receiving the reflected light from the gear by the emitted light from the light projecting unit, and means for performing hobbing using the tooth surface data and phase data obtained using the data based on the distance measured by this means."
[0004] Particularly in the gear processing machine of Patent Document 1, the sensor rotating unit "supports the laser displacement sensor so that it rotates about a sensor rotation axis that coincides with the laser light axis irradiated by the light projecting unit while maintaining a constant distance from the laser displacement sensor to the gear, and performs a rough adjustment to rotate the laser displacement sensor so that it is substantially perpendicular to the tooth row direction of the tooth surface of the gear that has been previously determined, and performs a fine adjustment to rotate the laser displacement sensor so that the diffused reflected light of the linear laser beam reflected from the gear is received most by the light receiving unit to determine the position of the laser displacement sensor."
Prior Art Documents
[0005] [Patent Document 1] Patent No. 6029163 [Overview of the project] [Problems that the invention aims to solve]
[0006] In the technology described in Patent Document 1, a laser displacement sensor is rotated so as to be approximately perpendicular to the tooth trace on the tooth surface of the gear. However, with this configuration, while tooth surface data and phase data of gears such as helical gears can be acquired, phase data of the tool cannot be acquired. Consequently, with the configuration of Patent Document 1, it is necessary to acquire tool phase data separately, which increases manufacturing costs as the number of devices increases.
[0007] One method for acquiring tool phase data is to mount the tool, which has been pre-adjusted outside the machine, onto the actual machine. However, in this method, manual work is involved when the operator mounts the pre-adjusted tool onto the actual machine, which may lead to mounting errors, setup errors, and mounting inaccuracies.
[0008] In view of the above circumstances, the present invention aims to provide a gear machining machine and a method for adjusting the phase of both the workpiece and the tool, which can adjust the phase of both the workpiece and the tool while minimizing the addition of components used for phase detection and preventing errors caused by manual work. [Means for solving the problem]
[0009] To solve the above problems, a typical configuration of the multi-tasking machine of the present invention comprises a fixed bed, a work spindle mounted on the fixed bed, a tool spindle mounted on the fixed bed, a phase detection device mounted on the fixed bed, and a control unit that controls the operation of the work spindle, tool spindle, and phase detection device. When the axis direction of the workpiece mounted on the work spindle is the work axis direction, the phase detection device comprises a base fixed to the fixed bed and a sensor unit that is movable on the base in the work axis direction. The sensor unit comprises a laser displacement sensor mounted at a predetermined angle inclined with respect to the work axis direction, and a sensor rotation unit that rotates the laser displacement sensor around the optical axis of the emitted light emitted from the laser displacement sensor. The control unit detects the phase of the workpiece mounted on the work spindle and the phase of the tool mounted on the tool spindle using the movement of the sensor unit in the work axis direction or the rotation of the laser displacement sensor by the sensor rotation unit.
[0010] The workpiece spindle described above is movable in the direction of the workpiece, and the workpiece is an external or internal gear. The laser of the laser displacement sensor is irradiated onto the tooth surface by moving the workpiece spindle in the direction of the workpiece. The tool described above may be a skiving cutter, a pinion cutter, or a hob cutter. [Effects of the Invention]
[0011] According to the present invention, it is possible to provide a gear machining machine and a method for adjusting the phase of both the workpiece and the tool while minimizing the number of additional parts used for phase detection and preventing errors caused by manual work. [Brief explanation of the drawing]
[0012] [Figure 1] This diagram schematically illustrates the configuration of the multi-tasking machine according to this embodiment. [Figure 2] This diagram illustrates the positional relationship between the workpiece or tool shown in Figure 1 and the sensor unit. [Figure 3] This is a flowchart illustrating the phase detection method for the workpiece shown in Figure 1. [Figure 4] Figure 2(c) is a flowchart illustrating the phase detection method for the skiving cutter. [Figure 5] Figure 2(d) is a flowchart illustrating the phase detection method of the hob cutter. [Modes for carrying out the invention]
[0013] Preferred embodiments of the present invention will be described in detail below with reference to the attached drawings. The dimensions, materials, and other specific numerical values shown in these embodiments are merely illustrative to facilitate understanding of the invention and do not limit the present invention unless otherwise specified. In this specification and drawings, elements having substantially the same function and configuration are denoted by the same reference numerals to avoid redundant explanations, and elements not directly related to the present invention are omitted from the illustrations.
[0014] (Multi-tasking machine 100) Figure 1 is a schematic diagram illustrating the configuration of the multi-tasking machine 100 according to this embodiment. The multi-tasking machine 100 of this embodiment has the function of machining gears by synchronously rotating the workpiece 200 and the tool 300. As shown in Figure 1, the multi-tasking machine 100 of this embodiment has a fixed bed 110, a workpiece spindle 120, a tool spindle 130, a phase detection device 140, and a control unit 190, all of which are installed on the fixed bed 110.
[0015] The workpiece spindle 120 is equipped with a replaceable workpiece 200, and rotates the mounted workpiece 200 around the workpiece axis C. In this embodiment, the workpiece spindle 120 of the multi-tasking machine 100 is movable in the workpiece axis direction Z (the same direction as the Z-axis direction described later), which is the axis direction of the workpiece axis C mounted on the workpiece spindle 120.
[0016] Specifically, the workpiece spindle 120 is positioned on the fixed bed 110 via a table 122, and a Z-axis drive screw 124 is inserted through the table 122. A Z-axis drive motor 126, which is the drive source for rotating the Z-axis drive screw 124, is connected to the Z-axis drive screw 124. As a result, driving the Z-axis drive motor 126 rotates the Z-axis drive screw 124, allowing the workpiece spindle 120 on the table 122 to move in the Z-axis direction (i.e., the Z-axis direction of the workpiece).
[0017] The tool spindle 130 is equipped with a replaceable tool 300, which rotates the attached tool 300 around the tool axis B. The tool spindle 130 is also movable in the X-axis direction (moving horizontally away from the tool axis C: front-back direction in the diagram) and the Y-axis direction (moving vertically away from the tool axis C: up-down direction in the diagram), and is rotatable in the A direction (rotation in a vertical plane parallel to the work axis C).
[0018] The control unit 190 controls the operation of the workpiece spindle 120, the tool spindle 130, and the phase detection device 140. Furthermore, as will be described later, in the multi-tasking machine 100 of this embodiment, the control unit 190 uses the phase detection device 140 to detect the phase of the workpiece 200 attached to the workpiece spindle 120 and the phase of the tool 300 attached to the tool spindle 130. Specifically, the control unit 190 uses the movement of the sensor unit 150 in the Z direction of the workpiece axis, or the rotation of the laser displacement sensor 152 by the sensor rotation unit 154, to detect the phase of the workpiece 200 and the phase of the tool 300.
[0019] The phase detection device 140 includes a pedestal 142 fixed to the fixed bed 110, a rail 144 disposed on the pedestal 142, and a sensor unit 150. The sensor unit 150 is movable to a measurement position and a retracted position by reciprocating in the direction of arrow S shown in FIG. 1 along the rail 144 disposed on the pedestal. The direction S is the same as the work axis direction Z described above. The measurement position is a position where the work 200 or the tool 300 can be irradiated with a laser. The retracted position is a position where it does not interfere with the work when the work 200 is machined by the tool 300 and is not exposed to coolant or chips.
[0020] FIG. 2 is a diagram for explaining the positional relationship between the work 200 or the tool 300 shown in FIG. 1 and the sensor unit 150. FIG. 2(a) illustrates the case of detecting the phase of the external gear 200a as the work 200 shown in FIG. 1. FIG. 2(b) illustrates the case of detecting the phase of the internal gear 200b as the work 200 shown in FIG. 1.
[0021] FIG. 2(c) illustrates the case of detecting the phase of the skiving cutter 300a as the tool 300 shown in FIG. 1. FIG. 2(d) illustrates the case of detecting the phase of the hob cutter 300b as the tool 300 shown in FIG. 1. In FIGS. 2(a)-(d), the upper part illustrates a plan view of the sensor unit 150 shown in FIG. 1 observed from above, and the lower part illustrates a side view of the sensor unit 150 shown in FIG. 1 observed from the side.
[0022] As shown in FIG. 1, the sensor unit 150 includes a laser displacement sensor 152 and a sensor rotating part 154. As shown in FIGS. 2(a)-(d), the laser displacement sensor 152 is attached in a state inclined at a predetermined angle θ with respect to the work axis C direction, and can irradiate the tooth surface with a laser whether the work is an external tooth or an internal tooth.
[0023] The sensor rotation unit 154 can rotate the laser displacement sensor 152 around the optical axis O of the emitted light from the laser displacement sensor 152, thereby rotating the laser displacement sensor 152 according to the tooth trace direction of the workpiece or tool. The laser displacement sensor 152 can irradiate the tool 300 with a laser by adjusting the position of the tool spindle 130, and can also irradiate the workpiece 200 with a laser by adjusting the position of the workpiece spindle 120.
[0024] (Phase detection operation in the multi-tasking machine 100) The phase detection operation of the workpiece 200 or tool 300 in the multi-tasking machine 100 of this embodiment will be described below with reference to the flowchart.
[0025] (Method for detecting the phase of workpiece 200) Figure 3 is a flowchart illustrating the phase detection method for the workpiece 200 shown in Figure 1. When detecting the phase of the workpiece 200, the control unit 190 first calculates the initial position of the workpiece spindle 120 and the initial position of the rotational phase of the laser displacement sensor 152 based on pre-acquired workpiece specifications (two-way tooth groove position, tooth width, number of teeth, tooth groove helix angle, etc.) (S402).
[0026] In detail, step S402 calculates the initial position of the workpiece spindle 120 by referring to whether the workpiece 200 is an external gear 200a or an internal gear 200b, i.e., the type of workpiece 200. If the workpiece 200 is an external gear 200a, the initial position of the workpiece spindle 120 is set so that the laser of the laser displacement sensor 152 is irradiated onto the tooth surface, which is the outer circumferential surface 202a of the workpiece 200, as shown in Figure 2(a). If the workpiece 200 is an internal gear 200b, the initial position of the workpiece spindle 120 is set so that the laser of the laser displacement sensor 152 is irradiated onto the tooth surface, which is the inner circumferential surface 202b of the workpiece 200, as shown in Figure 2(b).
[0027] Next, the control unit 190 moves the workpiece spindle 120 along the Z-axis to perform positioning based on the initial position calculated in step S402 (step S404). In this embodiment, the laser displacement sensor 152 is mounted at a predetermined angle of inclination with respect to the workpiece axis C direction. This makes it possible to irradiate the tooth surface of the workpiece 200 with the laser from the laser displacement sensor 152 by moving the workpiece spindle 120 in the Z-axis direction during positioning, regardless of whether the workpiece is an external gear 200a or an internal gear 200b.
[0028] In parallel with this, the control unit 190 positions the rotation phase of the laser displacement sensor 152 (step S406). In detail, it is preferable that the laser displacement sensor 152 has a tooth trace direction parallel to the straight line connecting the light-emitting unit that emits light and the light-receiving unit that detects reflected light. Therefore, the control unit 190 determines the direction of the laser displacement sensor 152 according to the direction of the tooth trace of the workpiece 200, controls the sensor rotation unit 154 to rotate the laser displacement sensor 152 around the optical axis O of the emitted light, and positions the laser displacement sensor 152 at the rotation position P1.
[0029] After positioning the workpiece spindle 120 and the laser displacement sensor 152 (steps S404 and S406), the control unit 190 rotates the workpiece spindle 120 while irradiating the tooth surface of the workpiece 200 (external gear 200a or internal gear 200b) with the laser from the laser displacement sensor 152 (step S408).
[0030] The control unit 190 determines whether or not the phase of the workpiece 200 was detected by the laser irradiation in step S408 (step S410). If the phase of the workpiece 200 was not detected (NO in step S410), the control unit 190 detects an abnormality, such as the predetermined workpiece 200 not being attached to the workpiece spindle 120 (step S416).
[0031] If the phase of the workpiece 200 is detected (YES in step S410), the control unit 190 stops the rotation of the workpiece spindle 120 (step S412). Then, the control unit 190 calculates the corrected rotation angle of the workpiece spindle 120 based on the detected phase of the workpiece 200 (step S414).
[0032] (Method for detecting the phase of tool 300 (skiving cutter 300a)) Figure 4 is a flowchart illustrating the phase detection method for the skiving cutter 300a shown in Figure 2(c). Processes common to the previously described phase detection method are denoted by the same reference numerals, thus omitting further explanation. Furthermore, the phase detection method for the skiving cutter 300a, as described using Figure 3, can also be used as a phase detection method for a pinion cutter (not shown).
[0033] When detecting the phase of the tool 300, the control unit 190 first calculates the initial position of the tool spindle 130 and the initial position of the rotational phase of the laser displacement sensor 152 based on pre-acquired tool specifications (Y-axis groove position, blade width, number of teeth, cutting angle, etc.) (step S502). The skiving cutter 300a has teeth formed in a gear shape around the tool axis B of the tool spindle 130 (perpendicular to the tooth trace direction of the workpiece 200). For this reason, the control unit 190 sets the laser displacement sensor 152 to a rotational position P2 that is perpendicular to the rotational position P1.
[0034] Next, the control unit 190 positions the tool spindle 130 (step S504) and the rotation phase of the laser displacement sensor 152 (step S506) based on the initial position calculated in S502. At this time, the control unit 190 controls the sensor rotation unit 154 to rotate the laser displacement sensor 152 around the optical axis O of the emitted light and position it at the rotation position P2.
[0035] After positioning the tool spindle 130 and the laser displacement sensor 152 (steps S504 and S506), the control unit 190 rotates the tool spindle 130 while irradiating the tool 300 with the laser from the laser displacement sensor 152 (step S508). The control unit 190 then determines whether or not the phase of the tool 300 has been detected by the laser irradiation (step S510).
[0036] If the phase of the tool 300 is not detected (NO in step S510), the control unit 190 detects an abnormality, such as the predetermined tool not being attached to the tool spindle 130 (step S416). If the phase of the tool 300 is detected (YES in S510), the control unit 190 stops the rotation of the tool spindle 130 (step S512). The control unit 190 then calculates the corrected rotation angle of the tool spindle 130 based on the detected phase of the tool 300 (step S514).
[0037] (Method for detecting the phase of tool 300 (hob cutter 300b)) Figure 5 is a flowchart illustrating the phase detection method for the hob cutter 300b shown in Figure 2(d). When detecting the phase of the hob cutter 300b, the control unit 190 first calculates the initial position of the tool spindle 130 and the initial position of the rotational phase of the laser displacement sensor 152 based on pre-acquired tool specifications (Y-axis groove position, blade width, number of grooves, number of teeth, lead angle, groove twist angle, etc.) (step S502). In the hob cutter 300b, the blade is formed in a spiral shape along a direction intersecting the axial direction (Y-axis direction) of the tool spindle 130.
[0038] In phase detection of the hob cutter 300b, the rake face of the hob cutter 300b's blade is detected by first rotating it along the B axis. Therefore, in positioning the rotation phase of the laser displacement sensor 152 in step S506, the control unit 190 controls the sensor rotation unit 154 to set the laser displacement sensor 152 to rotation position P2 (making the emitted light from the laser displacement sensor 152 parallel to the cutting edge direction of the hob cutter 300b).
[0039] The control unit 190 determines whether or not the rake face of the hob cutter 300b has been detected by irradiating it with a laser while rotating the B axis (step S508) (step S610). If the rake face is not detected (NO in step S610), the control unit 190 detects an abnormality (step S416). If the rake face is detected (YES in step S610), the control unit 190 stops the rotation of the tool spindle 130 at the position where the laser of the laser displacement sensor 152 has moved away from the rake face, specifically at the position where it has moved away from the rake face towards the flank face (step S612).
[0040] Next, the control unit 190 controls the sensor rotation unit 154 to rotate the laser displacement sensor 152 to the rotation position P1 (step S613). Then, the control unit moves the tool spindle 130 in the Y-axis direction while irradiating the laser of the laser displacement sensor 152 (step S614). Relatively speaking, this is equivalent to the laser scanning along the Y-axis direction of the tool 300 (hob cutter 300b). At this time, if the hob cutter 300b is of the twisted groove type, the tool spindle 130 is also rotated synchronously so that the distance between the relief surface of adjacent grooves and the laser displacement sensor 152 is always constant. When the phase of the tool 300 is detected (YES in step S510), the control unit 190 stops the movement of the tool spindle 130 (step S616).
[0041] As described above, the multi-tasking machine 100 of this embodiment allows for the detection of the phases of multiple types of workpieces 200 and multiple types of tools 300 using a single sensor unit 150. Therefore, the number of additional parts used for phase detection can be kept to a minimum, and the above-mentioned effects can be obtained while suppressing an increase in equipment costs. Furthermore, since no manual work is required when detecting the phases of the workpieces 200 and tools 300, it is possible to prevent errors caused by manual work.
[0042] Preferred embodiments of the present invention have been described above with reference to the attached drawings, but it goes without saying that the present invention is not limited to such examples. It will be obvious to those skilled in the art that various modifications or alterations can be conceived within the scope of the claims, and these will naturally also fall within the technical scope of the present invention. [Industrial applicability]
[0043] This invention can be used as a composite machining center that detects the phase of the workpiece and tool using a sensor unit. [Explanation of Symbols]
[0044] P1...Rotation position, 100...Multi-tasking machine, 110...Fixed bed, 120...Workpiece spindle, 122...Table, 124...Z-axis drive screw, 126...Z-axis drive motor, 130...Tool spindle, 140...Phase detection device, 142...Base, 144...Rail, 150...Sensor unit, 152...Laser displacement sensor, 154...Sensor rotation part, 190...Control unit, 200...Workpiece, 200a...External gear, 200b...Internal gear, 202a...Outer circumference, 202b...Inner circumference, 300...Tool, 300a...Skiving cutter, 300b...Hob cutter
Claims
1. Fixed bed and A work spindle installed on the aforementioned fixed bed, The tool spindle installed on the aforementioned fixed bed, A phase detection device installed on the aforementioned fixed bed, The system comprises a control unit that controls the operation of the work spindle, the tool spindle, and the phase detection device, When the axial direction of the workpiece mounted on the aforementioned workpiece spindle is the workpiece axis direction, The phase detection device is A base that is fixed to the aforementioned fixed bed, The base includes a sensor unit that is movable in the direction of the workpiece axis, The aforementioned sensor unit is A laser displacement sensor mounted at a predetermined angle inclined with respect to the workpiece axis, The system includes a sensor rotation unit that rotates the laser displacement sensor around the optical axis of the emitted light emitted from the laser displacement sensor, The control unit, The sensor unit is moved to the measurement position, and the laser displacement sensor is rotated to the rotation position according to the tooth trace direction of the workpiece or the cutting edge direction of the tool, thereby positioning the sensor unit. While rotating the workpiece spindle, the laser from the laser displacement sensor is irradiated onto the tooth surface of the workpiece to detect the phase of the workpiece. A gear machining composite machine characterized by detecting the phase of the tool by irradiating the tool with the laser of the laser displacement sensor while rotating the tool spindle or moving the tool spindle in the tool axis direction.
2. The workpiece spindle is movable in the direction of the workpiece, If the workpiece is an external gear, the initial position of the workpiece spindle is set so that the laser of the laser displacement sensor is irradiated onto the tooth surface, which is the outer circumferential surface of the workpiece. The gear machining composite machine according to claim 1, characterized in that, when the workpiece is an internal gear, the initial position of the workpiece spindle is set so that the laser of the laser displacement sensor is irradiated onto the tooth surface, which is the inner circumferential surface of the workpiece.
3. The gear machining multi-tasking machine according to claim 1, characterized in that the tool is a skiving cutter, a pinion cutter, or a hob cutter.