Machining load determination system

Abstract

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

Description

Processing load judgment system

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

[0002] There are industrial machines (e.g., machine tools, electric discharge machines, etc.) that have a movable part on which a tool or a workpiece is mounted and that machine the workpiece by moving the tool and the workpiece relative to each other. For such industrial machines, there is a technology that performs a machining simulation using a virtual space that reproduces an environment similar to the environment in which actual machining is performed using a three-dimensional model, and checks for any problems in the operating data (e.g., machining program).

[0003] In such technology, various factors can cause unintended differences between the 3D model in the virtual space defined for simulation and the actual environment. For example, the workpiece may float during machining in the actual environment, or tool wear compensation may not be reflected in the 3D model in the virtual space. In such cases, differences may occur between the results obtained by the simulation and the results obtained in actual machining.

[0004] In this regard, Patent Document 1 discloses a technology in which a real machine unit and a simulation unit are arranged in parallel, the same command is input to both the real machine unit and the simulation unit, internal state quantities of the real machine unit and the simulation unit are compared, and the internal state quantity comparison value is compared with a preset detection threshold value to detect contact or collision of a moving part with another object. It is believed that this technology can detect whether there is a difference between the results obtained by simulation and the results obtained in actual machining. Patent Document 1 also discloses that the calculation formula of the simulation unit's model is simple, resulting in a short processing time.

[0005] Japanese Patent Application Laid-Open No. 2004-364396

[0006] In the technology disclosed in Patent Document 1, the simulation of the simulation unit must be performed in real time in accordance with the operation of the actual machine. The processing time for a simulation using a three-dimensional model as a virtual space is relatively long. Therefore, in the technology disclosed in Patent Document 1, as described above, the calculation formula of the model of the simulation unit is simplified to shorten the processing time in accordance with the operation time of the actual machine.

[0007] As described above, the accuracy of the simulation is limited in a real-time simulation of actual machining. As a result, it may not be possible to correctly detect the difference between the simulation and the actual machining. Therefore, it is desired to improve the accuracy of detecting the difference between the simulation and the actual machining without limiting the accuracy of the simulation.

[0008] The machining load determination system of the present disclosure includes an actual machining unit having a movable unit on which a tool or a workpiece is mounted, and machining the workpiece by moving the tool and the workpiece relative to each other based on operation data; a simulation unit that performs a machining simulation of the virtual workpiece by moving the virtual tool and the virtual workpiece relative to each other based on the operation data in a virtual space including virtual tools, virtual workpieces, and virtual moving units corresponding to the tool, the workpiece, and the moving unit, respectively; a virtual load acquisition unit that acquires virtual load information occurring on the virtual moving unit, obtained by the machining simulation by the simulation unit; an actual load acquisition unit that acquires actual load information occurring on the moving unit, obtained by machining by the actual machining unit; and a load information determination unit that compares the virtual load information with the actual load information and determines whether there is a difference between these pieces of information. The simulation unit calculates the virtual load information and comparison point identification data that identifies the comparison point between the virtual load information and the actual load information, the virtual load acquisition unit acquires the virtual load information in association with the comparison point identification data, the actual load acquisition unit acquires the actual load information in association with the comparison point identification data, and the load information determination unit compares the virtual load information with the actual load information based on the comparison point identification data.

[0009] 1 is a diagram illustrating an overview of an industrial machinery system according to an embodiment of the present invention; FIG. 2 is a diagram illustrating a configuration of a machining load determination system according to an embodiment of the present invention; FIG. 3 is a diagram illustrating an example of virtual load information and comparison location identification data; FIG. 4 is a diagram illustrating an example of actual load information and comparison location identification data; FIG. 5 is a diagram illustrating Example 1 of machining load determination processing by the machining load determination system according to an embodiment of the present invention (when there is no difference between the actual machining unit and the simulation unit); FIG. 6 is a diagram illustrating Example 1 of machining load determination processing by the machining load determination system according to an embodiment of the present invention (when there is a difference between the actual machining unit and the simulation unit: a pattern in which contact is detected only in the simulation unit); FIG. 7 is a diagram illustrating Example 1 of machining load determination processing by the machining load determination system according to an embodiment of the present invention (when there is a difference between the actual machining unit and the simulation unit: a pattern in which contact is detected only in the actual machining unit); FIG. 8 is a diagram illustrating Example 2 of machining load determination processing by the machining load determination system according to an embodiment of the present invention (when there is no difference between the actual machining unit and the simulation unit); FIG. 9 is a diagram illustrating Example 2 of machining load determination processing by the machining load determination system according to an embodiment of the present invention (when there is a difference between the actual machining unit and the simulation unit: a pattern in which workpiece lift-up occurs). FIG. 10 is a diagram showing Example 2 of the machining load judgment process by the machining load judgment system according to the present embodiment (when there is a difference between the actual machining unit and the simulation unit: a pattern in which contact is detected only at the actual machining unit); FIG. 11 is a diagram showing Example 3 of the machining load judgment process by the machining load judgment system according to the present embodiment (when there is no difference between the actual machining unit and the simulation unit); FIG. 12 is a diagram showing Example 3 of the machining load judgment process by the machining load judgment system according to the present embodiment (when there is a difference between the actual machining unit and the simulation unit: a pattern in which contact is detected only at the simulation unit); FIG. 13 is a diagram showing Example 4 of the machining load judgment process by the machining load judgment system according to the present embodiment (when there is a difference between the actual machining unit and the simulation unit: a pattern in which contact is detected only at the actual machining unit);FIG. 10 is a diagram illustrating Example 5 of the processing load determination process by the processing load determination system according to the present embodiment.

[0010] An example of this embodiment will be described below with reference to the accompanying drawings, in which the same or equivalent parts are designated by the same reference numerals.

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

[0012] The machine tool 130 is an actual machining unit, which will be described later, and performs removal machining of the workpiece W by moving the tool T and the workpiece W relative to each other based on operation data. Below, an M-series (machining center) machine is used as an example of the machine tool, but this embodiment is not limited to this. This embodiment can also be applied to a T-series (lathe) machine tool. Below, a machine tool is used as an example of the industrial machine, but this embodiment is not limited to this. This embodiment can also be applied to various industrial machines, such as electric discharge machines, in which the tool T and the workpiece W come into contact with each other to machine the workpiece W.

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

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

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

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

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

[0018] The actual machining unit 12 is the above-mentioned machine tool 130. As described above, the actual machining unit 12 uses the mounting unit 134 on which the tool T is mounted or the table 136 on which the workpiece W is mounted as a movable unit, and performs machining of the workpiece W by moving the tool T and the workpiece W relative to each other based on operation data.

[0019] The simulation unit 14 may be provided in the above-described numerical control device 110, or may be configured as a computer separate from the numerical control device 110. For example, as shown in FIG. 4A (described later), the simulation unit 14 includes a virtual space VS including a virtual tool Ts, a virtual workpiece Ws, a virtual mounting portion (virtual movable portion) 134s, and a table (virtual movable portion) 136s, which respectively simulate the tool T, workpiece W, mounting portion (movable portion) 134, and table (movable portion) 136 of the actual machining unit 12. The simulation unit 14 performs a machining simulation of the virtual workpiece Ws by moving the virtual tool Ts and the virtual workpiece Ws relative to each other in the virtual space VS based on operation data. As shown in FIG. 3A (FIG. 3A), the simulation unit 14 calculates virtual load information generated on the virtual movable portions 134s and 136s and comparison location identification data that identifies comparison locations between the virtual load information and the actual load information. Details of the virtual load information and the comparison location identification data will be described later.

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

[0021] The virtual load acquiring unit 18 may be provided in the above-described numerical control device 110, or may be provided in a computer constituting the simulation unit 14, or may be constituted by a computer different from the numerical control device 110 and the simulation unit 14. As shown in Fig. 3A, the virtual load acquiring unit 18 acquires virtual load information generated on the virtual moving parts 134s, 136s obtained by the machining simulation by the simulation unit 14. Specifically, the virtual load acquiring unit 18 acquires the virtual load information in association with the comparison portion identification data.

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

[0023] The operation control unit 24 is provided in the above-mentioned drive unit (servo control unit) 130. When the load information determination unit 22 determines that there is a difference between the virtual load information and the actual load information, the operation control unit 24 performs at least one of the following in the actual machining unit 12: limiting the output for operating the movable units 134, 136 (for example, torque limitation), performing a retraction operation (retraction) of the movable units 134, 136 that is set in advance in the machining program, or immediately decelerating and stopping the operation of the movable units 134, 136.

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

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

[0026] The storage unit 20 is configured with memory such as a read-only memory (ROM), a hard disk drive (HDD), or a solid state drive (SSD). The storage unit 20 stores predetermined software (programs) that realize the various functions of the simulation unit 14, the actual load acquisition unit 16, the virtual load acquisition unit 18, the load information determination unit 22, the operation control unit 24, and the correction unit 26. The storage unit 20 also stores the virtual load information and comparison point identification data shown in FIG. 3A acquired by the virtual load acquisition unit 18, and the actual load information and comparison point identification data shown in FIG. 3B acquired by the actual load acquisition unit 16.

[0027] The display unit 28 is configured, for example, with a liquid crystal display or an organic EL display. The display unit 28 displays the comparison point identification data for which the load information determination unit 22 has determined that there is a difference between the virtual load information and the actual load information in a different display mode according to the difference. For example, the display unit 28 highlights a block in the program (operation data) corresponding to the comparison point identification data for which there is a difference between the virtual load information and the actual load information in a display mode (for example, color, blinking, etc.) that is different from that for blocks with no difference.

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

[0029] [Example 1] In Example 1, the elapsed time (time information) of program operation is used as comparison point identification data. Fig. 4A is a diagram showing a case where there is no difference between the actual load information of the moving part in the actual machining unit and the virtual load information of the virtual moving part in the simulation unit, Fig. 4B is a diagram showing a case where there is a difference between the actual load information of the moving part in the actual machining unit and the virtual load information of the virtual moving part in the simulation unit (a pattern where contact is detected only in the simulation unit), Fig. 4C is a diagram showing a case where there is a difference between the actual load information of the moving part in the actual machining unit and the virtual load information of the virtual moving part in the simulation unit (a pattern where contact is detected only in the actual machining unit), and Fig. 4D is a diagram showing a case where there is a difference between the actual load information of the moving part in the actual machining unit and the virtual load information of the virtual moving part in the simulation unit (a pattern where the workpiece floats up).

[0030] (When there is no difference between the actual machining unit and the simulation unit) <1-1> As shown in FIG. 4A , for example, the numerical control device 110 analyzes the machining program and generates time-series data Xs(0), Xs(1) to Xs(n) of the machine coordinates Xs(i) of the virtual movable units 134s and 136s after time Ts(i) seconds from the start time Ts(0) as operation data for the simulation unit 14, and outputs the data to the simulation unit 14. Furthermore, for example, the numerical control device 110 analyzes the machining program and generates time-series data Xr(0), Xr(1) to Xr(n) of the machine coordinates Xr(j) of the movable units 134 and 136 after time Tr(j) seconds from the start time Tr(0) as operation data for the actual machining unit 12, and outputs the data to the drive unit 120. Here, i and j are any integers from 1 to n, and n is an integer equal to or greater than 1. Xs(i) and Xr(j) are q-dimensional arrays, and the mechanical coordinate of the p-th axis of the virtual moving part can be expressed as Xsp(i), and the mechanical coordinate of the p-th axis of the moving part can be expressed as Xrp(j). q is an integer of 1 or more and indicates the number of axes of the machine. p is an arbitrary integer from 1 to q.

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

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

[0033] The simulation unit 14 calculates contact information indicating whether the virtual tool Ts and the virtual workpiece Ws are in contact with each other as virtual load information generated on the virtual movable parts 134s, 136s at a certain machine coordinate Xs(i) at a certain time Ts(i). For example, the simulation unit 14 sets the contact flag to 0 when the virtual tool Ts is outside the virtual workpiece Ws, and sets the contact flag to 1 when the virtual tool Ts moves from the outside to the inside of the virtual workpiece Ws.

[0034] The simulation unit 14 also calculates a certain time Ts(i) as comparison location identification data that identifies a comparison location between the virtual load information and the actual load information. Specifically, the comparison location identification data is data that associates the virtual load information with the actual load information in terms of time series or machining positions. More specifically, the comparison location identification data is data that establishes a one-to-one correspondence between the time Ts(i) at which the virtual tool Ts and the virtual workpiece Ws come into contact in the simulation unit 14 and the time Tr(j) at which the tool T and the workpiece W come into contact in the actual machining unit 12. That is, the comparison location identification data is data that identifies the time Ts(i) and the time Tr(j) as comparison locations between the virtual load information and the actual load information. This allows the load information determination unit 22 to appropriately compare the virtual load information at time Ts(i) with the actual load information at time Tr(j) based on the comparison location identification data. As described above, the simulation unit 14 may be provided in the numerical control device 110 or may be configured by a computer separate from the numerical control device 110.

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

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

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

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

[0039] The driving unit 120 (actual load acquiring unit 16) acquires the contact signal (actual load information) in association with the time Tr(j) (comparison point specifying data).

[0040] <1-4> The numerical control device 110 (load information determination unit 22) compares the contact signal (actual load information) with the contact flag (virtual load information) based on times Tr(j) and Ts(i) (comparison point identification data) and determines whether there is a difference between these pieces of information. For example, in Fig. 4A, the numerical control device 110 (load information determination unit 22) acquires the contact signal (actual load information) between times Ts(i-1) and Ts(i) based on times Tr(j) and Ts(i) (comparison point identification data), and because the contact flag (virtual load information) at this time is 1, it determines that there is no difference between these pieces of information.

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

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

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

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

[0045] Typically, the acquisition period for the position of the movable part in the actual machining unit is shorter than the simulation period, so it is possible to ignore the error (delay time) in the time Tr(j) at which the contact signal is detected in the actual machining unit 12. However, if the error (delay time) of the actual machining unit is smaller than the error of the simulation unit 14, the load information determination unit 22 may determine that there is no difference between the actual load information and the virtual load information if there is a time Ts(i) at which the contact flag becomes 1 in the simulation unit 14 between times Tr(j-1) and Tr(j) in the actual machining unit 12.

[0046] Furthermore, in addition to the determination based on the contact time described above, the load information determination unit 22 may also determine that there is no difference between the actual load information and the virtual load information based on a determination based on the contact position as follows. For example, the load information determination unit 22 may further determine that there is no difference between the actual load information and the virtual load information when the machine coordinate Xr(j) at which a contact signal is detected in the actual machining unit 12 and the machine coordinates Xs(i-1), Xs(i) at which the contact flag changes from 0 to 1 in the simulation unit 14 satisfy the following equation for all axes p in operation between i-1 and i: |Xrp(j) - Xsp(i)| ≤ |Xsp(i) - Xsp(i-1)| This makes it possible to eliminate cases where the contact times (collision times) happen to match as a result of multiple mistakes.

[0047] 4B , for example, the numerical control device 110, similar to the above, generates time-series data Xs(0), Xs(1) to Xs(n) of the machine coordinates Xs(i) of the virtual movable parts 134s, 136s after the time Ts(i) seconds from the start time Ts(0) as operation data for the simulation part 14. Also, for example, the numerical control device 110, similar to the above, generates time-series data Xr(0), Xr(1) to Xr(n) of the machine coordinates Xr(j) of the movable parts 134, 136 after the time Tr(j) seconds from the start time Tr(0) as operation data for the actual machining part 12.

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

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

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

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

[0052] At this time, the machine tool operator can recognize whether the tool T has been attached incorrectly or is damaged by comparing the machine coordinates where contact (interference) was detected in the machining simulation and the machine coordinates where no contact (interference) was detected in the actual machining with the machine coordinates where contact (interference) was detected in the actual machining.

[0053] 4C , for example, the numerical control device 110, similar to the above, generates time-series data Xs(0), Xs(1) to Xs(n) of the machine coordinates Xs(i) of the virtual movable parts 134s, 136s after the time Ts(i) seconds from the start time Ts(0) as operation data for the simulation part 14. Also, for example, the numerical control device 110, similar to the above, generates time-series data Xr(0), Xr(1) to Xr(n) of the machine coordinates Xr(j) of the movable parts 134, 136 after the time Tr(j) seconds from the start time Tr(0) as operation data for the actual machining part 12.

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

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

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

[0057] As described above, if there is a difference between the actual load information and the virtual load information, the numerical control device 110 (motion control unit 24) decelerates and stops the machine tool 130.

[0058] 4C , for example, the numerical control device 110, similar to the above, generates time-series data Xs(0), Xs(1) to Xs(n) of the machine coordinates Xs(i) of the virtual movable parts 134s, 136s from the start time Ts(0) to the time Ts(i) seconds later as operation data for the simulation part 14. In addition, for example, the numerical control device 110, similar to the above, generates time-series data Xr(0), Xr(1) to Xr(n) of the machine coordinates Xr(j) of the movable parts 134, 136 from the start time Tr(0) to the time Tr(j) seconds later as operation data for the actual machining part 12.

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

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

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

[0062] As described above, if there is a difference between the actual load information and the virtual load information, the numerical control device 110 (motion control unit 24) decelerates and stops the machine tool 130.

[0063] [Example 2] In Example 2, machine coordinates (position information of the moving part) are used as comparison point identification data. This makes it possible to accurately determine whether there is a difference between the actual load information and the virtual load information, even when there is a significant difference in time (delay) between the simulation and actual machining due to factors external to the machine tool. Figure 5A is a diagram showing a case where there is no difference between the actual load information of the moving part in the actual machining part and the virtual load information of the virtual moving part in the simulation part. Figure 5B is a diagram showing a case where there is a difference between the actual load information of the moving part in the actual machining part and the virtual load information of the virtual moving part in the simulation part (a pattern in which contact is detected only in the simulation part). Figure 5C is a diagram showing a case where there is a difference between the actual load information of the moving part in the actual machining part and the virtual load information of the virtual moving part in the simulation part (a pattern in which contact is detected only in the actual machining part).

[0064] 5A , for example, the numerical control device 110 analyzes the machining program and generates time-series data Xs(0), Xs(1) to Xs(n) of the machine coordinates Xs(i) of the virtual movable parts 134s and 136s from the start time Ts(0) to the time Ts(i) seconds later as operation data for the simulation unit 14, and outputs the data to the simulation unit 14. Furthermore, for example, the numerical control device 110 analyzes the machining program and generates time-series data Xr(0), Xr(1) to Xr(n) of the machine coordinates Xr(j) of the movable parts 134 and 136 from the start time Tr(0) to the time Tr(j) seconds later as operation data for the actual machining unit 12, and outputs the data to the drive unit 120. Here, i and j are any integers from 1 to n, and n is an integer equal to or greater than 1.

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

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

[0067] The simulation unit 14 calculates contact information indicating whether the virtual tool Ts and the virtual workpiece Ws are in contact with each other as virtual load information generated on the virtual movable parts 134s, 136s at a certain machine coordinate Xs(i) at a certain time Ts(i). For example, the simulation unit 14 sets the contact flag to 0 when the virtual tool Ts is outside the virtual workpiece Ws, and sets the contact flag to 1 when the virtual tool Ts moves from the outside to the inside of the virtual workpiece Ws.

[0068] The simulation unit 14 also calculates a machine coordinate Xs(i) at a certain time Ts(i) as comparison location identification data that identifies a comparison location between the virtual load information and the actual load information. Specifically, the comparison location identification data is data that associates the virtual load information with the actual load information in terms of time series or machining positions. More specifically, the comparison location identification data is data that establishes a one-to-one correspondence between the machine coordinate Xs(i) at which the virtual tool Ts and the virtual workpiece Ws contact in the simulation unit 14 and the machine coordinate Xr(j) at which the tool T and the workpiece W contact in the actual machining unit 12. In other words, the comparison location identification data is data that identifies the machine coordinate Xs(i) and the machine coordinate Xr(j) as comparison locations between the virtual load information and the actual load information. This allows the load information determination unit 22 to appropriately compare the virtual load information at the machine coordinate Xs(i) with the actual load information at the machine coordinate Xr(j) based on the comparison location identification data. As described above, the simulation unit 14 may be provided in the numerical control device 110 or may be configured by a computer different from the numerical control device 110.

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

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

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

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

[0073] The driving unit 120 (actual load acquiring unit 16) acquires the contact signal (actual load information) in association with the machine coordinates Xr(j) (comparison point specifying data).

[0074] <2-4> The numerical control device 110 (load information determination unit 22) compares the contact signal (actual load information) with the contact flag (virtual load information) based on the machine coordinates Xr(j), Xs(i) (comparison point identification data) and determines whether there is a difference between these pieces of information. For example, in Fig. 5A, the numerical control device 110 (load information determination unit 22) determines that there is no difference between the actual load information and the virtual load information based on the machine coordinates Xr(j), Xs(i) (comparison point identification data), because the machine coordinate Xr(j) (comparison point identification data) at which the contact signal (actual load information) is detected in the actual machining unit 12 and the machine coordinates Xs(i-1), Xs(i) (comparison point identification data) at which the contact flag (virtual load information) changes from 0 to 1 in the simulation unit 14 satisfy the following inequality for all axes p operating between i-1 and i: |Xrp(j)-Xsp(i)|≦|Xsp(i)-Xsp(i-1)|

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

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

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

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

[0079] 5B , for example, the numerical control device 110, similar to the above, generates time-series data Xs(0), Xs(1) to Xs(n) of the machine coordinates Xs(i) of the virtual movable parts 134s, 136s after the time Ts(i) seconds from the start time Ts(0) as operation data for the simulation part 14. Also, for example, the numerical control device 110, similar to the above, generates time-series data Xr(0), Xr(1) to Xr(n) of the machine coordinates Xr(j) of the movable parts 134, 136 after the time Tr(j) seconds from the start time Tr(0) as operation data for the actual machining part 12.

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

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

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

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

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

[0085] At this time, the machine tool operator can recognize whether the tool T has been attached incorrectly or is damaged by comparing the machine coordinates where contact (interference) was detected in the machining simulation and the machine coordinates where no contact (interference) was detected in the actual machining with the machine coordinates where contact (interference) was detected in the actual machining.

[0086] 5C , for example, the numerical control device 110, similar to the above, generates time-series data Xs(0), Xs(1) to Xs(n) of the machine coordinates Xs(i) of the virtual movable parts 134s, 136s after the time Ts(i) seconds from the start time Ts(0) as operation data for the simulation part 14. Also, for example, the numerical control device 110, similar to the above, generates time-series data Xr(0), Xr(1) to Xr(n) of the machine coordinates Xr(j) of the movable parts 134, 136 after the time Tr(j) seconds from the start time Tr(0) as operation data for the actual machining part 12.

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

[0088] In addition, if contact is detected at another location after machining has progressed to a certain extent, the numerical control device 110 (virtual load acquisition unit 18) may acquire contact flag 1 (virtual load information) in association with the machine coordinate Xs(k) (comparison location identification data) where the contact was detected.

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

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

[0091] As described above, if there is a difference between the actual load information and the virtual load information, the numerical control device 110 (motion control unit 24) decelerates and stops the machine tool 130.

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

[0093] 6A , for example, the simulation unit 14 analyzes the machining program and generates time-series data Xs(0), Xs(1) to Xs(n) of the machine coordinates Xs(i) of the virtual movable units 134s and 136s from the start time Ts(0) to the time Ts(i) seconds later as operation data for the simulation unit 14. Meanwhile, for example, the numerical control device 110 analyzes the machining program and generates time-series data Xr(0), Xr(1) to Xr(n) of the machine coordinates Xr(j) of the movable units 134 and 136 from the start time Tr(0) to the time Tr(j) seconds later as operation data for the actual machining unit 12, and outputs the data to the drive unit 120. Here, i and j are any integers from 1 to n, and n is an integer equal to or greater than 1.

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

[0095] The simulation unit 14 calculates contact information indicating whether the virtual tool Ts and the virtual workpiece Ws are in contact with each other at a certain machine coordinate Xs(i) at a certain time Ts(i) as virtual load information occurring on the virtual movable parts 134s and 136s. The simulation unit 14 also calculates a certain machine coordinate Xs(i) at a certain time Ts(i) as comparison location identification data that identifies a location to compare the virtual load information with the actual load information. For example, if the virtual tool Ts invades the virtual workpiece Ws from the outside to the inside between the machine coordinates Xs(j-1) and Xs(j), the simulation unit 14 adds the coordinate of the machine coordinate Xs(j) to the command block in the operation data in the format ",Ln X_Y_Z_" (virtual load information and comparison location identification data). Here, n is an integer greater than or equal to 1. If contact occurs multiple times within one block, n is incremented and multiple entries are made.

[0096] In addition, when the operation data is a minute line segment, the coordinates of the machine coordinates Xs(j) may be added in units of one block instead of in units of command blocks (virtual load information and comparison point specifying data). Also, although the example has been given for a case where there are three feed axes, this embodiment can also be applied to a case where there are four or more feed axes.

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

[0098] The numerical control device 110 (virtual load acquisition unit 18) acquires ", Ln X_Y_Z_" (virtual load information and comparison location identification data) added to the operation data as shown in FIG. 6A.

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

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

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

[0102] The driving unit 120 (actual load acquiring unit 16) acquires the contact signal (actual load information) in association with the machine coordinates Xr(j) (comparison point specifying data).

[0103] <3-4> The numerical control device 110 (load information determination unit 22) compares the contact signal (actual load information) with the presence or absence of contact (virtual load information) based on the machine coordinates Xr(j) and Xs(i) (comparison point identification data), and determines whether there is a difference between these pieces of information. For example, in Figure 6A, the numerical control device 110 (load information determination unit 22) determines that there is no difference between the actual load information and the virtual load information because the machine coordinate Xr(j) (comparison point identification data) at which the contact signal (actual load information) was detected in the actual machining unit 12 and the machine coordinate Xs(i) (comparison point identification data) indicated by ",Ln X_Y_Z_" added to the operation data in the simulation unit 14 satisfy the following inequality for all axes p operating between i-1 and i: |Xrp(j) - Xsp(i)| ≦ |Xsp(i) - Xsp(i-1)| Note that if the operation data contains multiple ",Ln X_Y_Z_" (virtual load information and comparison point identification data), the above judgment can be made in order of the smallest value of n.

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

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

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

[0107] 6B , for example, the simulation unit 14, similarly to the above, generates time-series data Xs(0), Xs(1) to Xs(n) of the machine coordinates Xs(i) of the virtual movable parts 134s, 136s from the start time Ts(0) to the time Ts(i) seconds later as operation data for the simulation unit 14. On the other hand, for example, the numerical control device 110, similarly to the above, generates time-series data Xr(0), Xr(1) to Xr(n) of the machine coordinates Xr(j) of the movable parts 134, 136 from the start time Tr(0) to the time Tr(j) seconds later as operation data for the actual machining unit 12.

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

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

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

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

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

[0113] 6C , for example, the simulation unit 14, similarly to the above, generates time-series data Xs(0), Xs(1) to Xs(n) of the machine coordinates Xs(i) of the virtual movable parts 134s, 136s from the start time Ts(0) to the time Ts(i) seconds later as operation data for the simulation unit 14. On the other hand, for example, the numerical control device 110, similarly to the above, generates time-series data Xr(0), Xr(1) to Xr(n) of the machine coordinates Xr(j) of the movable parts 134, 136 from the start time Tr(0) to the time Tr(j) seconds later as operation data for the actual machining unit 12.

[0114] <3-2> As described above, the simulation unit 14 performs a machining simulation of the virtual workpiece Ws, and the numerical control device 110 (virtual load acquisition unit 18) acquires ",Ln X_Y_Z_" (virtual load information and comparison location identification data) added to the operation data as shown in Fig. 6C. For example, in Fig. 6C, the virtual tool Ts does not invade the virtual workpiece Ws from the outside to the inside, and the operation data does not include ",Ln X_Y_Z_" (virtual load information and comparison location identification data), so the numerical control device 110 (virtual load acquisition unit 18) does not acquire ",Ln X_Y_Z_" (virtual load information and comparison location identification data) added to the operation data.

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

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

[0117] As described above, if there is a difference between the actual load information and the virtual load information, the numerical control device 110 (motion control unit 24) decelerates and stops the machine tool 130.

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

[0119] In Example 4, the magnitude of the load (energy) generated on the moving part when machining a workpiece is used as the actual load information, and the magnitude of the load (energy) generated on the virtual moving part when machining a virtual workpiece is used as the virtual load information. By acquiring the magnitude of the load (energy) instead of the presence or absence of contact, it becomes possible to more accurately determine contact between the tool and the workpiece, for example, when cutting in gradually.

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

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

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

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

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

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

[0126] Vs(i) is the volume of the removal area, which is the overlapping area between the area through which the virtual tool Ts passed and the area of ​​the virtual workpiece Ws between Ts(i-1) and Ts(i). Vs(i) is the speed of i and can be expressed by the following formula:

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

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

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

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

[0131] The drive unit 120 (actual load acquisition unit 16) calculates the total motor load Wr(j) [J / s] (energy Wr×t) as actual load information occurring on the movable units 134, 136 at a certain machine coordinate Xr(j) at a certain time Tr(j). The calculation of the load Wr(j) [J / s] (energy Wr×t) may be similar to the example of the calculation of the load Ws(i) [J / s] (energy Ws×t) described above.

[0132] If the machine tool is an electric discharge machine, the power flowing through the tool can be added to the total load of the motor.

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

[0134] <4-4> The numerical control device 110 (load information determination unit 22) compares the load Wr(j) [J / s] (energy Wr×t) (actual load information) with the load Ws(i) [J / s] (energy Ws×t) (virtual load information) based on the times Tr(j) and Ts(i) (comparison point identification data), and determines whether there is a difference between these pieces of information. For example, in FIG. 7, the numerical control device 110 (load information determination unit 22) finds the minimum j (jmin) and maximum j (jmax) that satisfy the following formula at the time Ts(i): Ts(i-1)≦Tr(j)<Ts(i)

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

[0136] If the motor output is smaller than a certain threshold value, it may be assumed that the workpiece and the tool are not in contact with each other in the actual machining area, and no comparison may be performed.

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

[0138] If there is no difference between the actual load information and the virtual load information, the numerical control device 110 (operation control unit 24) does not impose any operational restrictions.

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

[0140] [Example 5] In the above-described Examples 1 to 4, an example was given in which the operation of the actual machining is restricted on the assumption that there is a problem in the actual machining. In Example 5, when there is a problem in the settings of the machining simulation, the settings of the machining simulation are changed (corrected). In this way, by reflecting the difference between the actual load information and the virtual load information in the machining simulation, it is possible to improve the simulation accuracy.

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

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

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

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

[0145] The driving unit 120 (actual load acquiring unit 16) acquires the contact signal (actual load information) in association with the machine coordinates Xr(j) (comparison point specifying data).

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

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

[0148] The simulation unit 14 calculates contact information indicating whether the virtual tool Ts and the virtual workpiece Ws are in contact with each other as virtual load information generated on the virtual movable parts 134s, 136s at a certain machine coordinate Xs(i) at a certain time Ts(i). For example, the simulation unit 14 sets the contact flag to 0 when the virtual tool Ts is outside the virtual workpiece Ws, and sets the contact flag to 1 when the virtual tool Ts moves from the outside to the inside of the virtual workpiece Ws.

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

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

[0151] <5-4> The simulation unit 14 (load information determination unit 22) compares the contact signal (actual load information) with the contact flag (virtual load information) based on the machine coordinates Xr(j), Xs(i) (comparison point identification data), and determines whether there is a difference between these pieces of information. For example, in Fig. 8, the numerical control device 110 (load information determination unit 22) determines, based on the machine coordinates Xr(j), Xs(i) (comparison point identification data), that there is a difference between the actual load information and the virtual load information when the machine coordinate Xr(j) (comparison point identification data) at which the contact signal (actual load information) is detected in the actual machining unit 12 is different from the machine coordinate Xs(i) (comparison point identification data) at which the contact flag (virtual load information) changes from 0 to 1 in the simulation unit 14.

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

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

[0154] For example, in Figure 8, the simulation unit 14 (correction unit 26) calculates the difference between the machine coordinate in the simulation unit 14 corresponding to the machine coordinate Xr(j) at which a contact signal (actual load information) was detected in the actual machining unit 12 and the machine coordinate of the boundary of the virtual workpiece Ws, and reflects this difference in the preconditions of the simulation unit so as to change the setting value of the radius R of the virtual tool Ts.

[0155] Alternatively, the simulation unit 14 (correction unit 26) may calculate the difference between the machine coordinate Xr(j) at which a contact signal (actual load information) is detected in the actual machining unit 12 and the machine coordinate Xs(i) at which a contact flag (virtual load information) is detected in the simulation unit 14, and use this difference as a correction amount for the virtual tool Ts, and reflect this in the simulation unit's preconditions so that the setting value of the virtual tool Ts is changed (corrected) by this correction amount.

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

[0157] As described above, the machining load determination system 10 of this embodiment acquires virtual load information of a machining simulation in association with comparison location identification data, and acquires actual load information of an actual machining in association with comparison location identification data. Therefore, it is possible to appropriately compare these load information based on the comparison location identification data without performing a machining simulation in real time for the actual machining. Therefore, it is possible to perform a machining simulation in advance before the actual machining, eliminating the need to shorten the processing time of the machining simulation to match the operating time of the actual machining. This eliminates limitations on the accuracy of the machining simulation, i.e., it is possible to improve the accuracy of the machining simulation. Therefore, it is possible to improve the accuracy of detecting differences between the machining simulation and the actual machining, and correctly detect malfunctions that were previously unpreventable.

[0158] In the technology disclosed in Patent Document 1, when the same operation is repeated using the same operation data, the same simulation must be constantly performed, which requires resources. In this regard, in the present embodiment, it is not necessary to perform a machining simulation every time actual machining is performed, and resources can be reduced compared to the technology disclosed in Patent Document 1.

[0159] Although the present disclosure has been described in detail, the present disclosure is not limited to the individual embodiments described above. Various additions, substitutions, modifications, partial deletions, etc. are possible in these embodiments without departing from the gist of the present disclosure or the spirit of the present disclosure derived from the content of the claims and their equivalents. These embodiments can also be implemented in combination. For example, in the above-described embodiments, the order of each operation and the order of each process are shown as examples and are not limited to these. The same applies when numerical values ​​or mathematical expressions are used in the description of the above-described embodiments.

[0160] The following additional notes are provided regarding the above-described embodiment and modifications. (Supplementary Note 1) A machining load determination system (10) includes: an actual machining unit (12) having a movable unit (134, 136) on which a tool (T) or a workpiece (W) is provided, and machining the workpiece (W) by relatively moving the tool (T) and the workpiece (W) based on operation data; a simulation unit (14) that performs a machining simulation of the virtual workpiece (Ws) by relatively moving the virtual tool (Ts) and the virtual workpiece (Ws) based on the operation data in a virtual space (VS) including virtual tools (Ts), virtual workpieces (Ws), and virtual movable units (134s, 136s) corresponding to the tool (T), the workpiece (W), and the movable unit (134, 136), respectively; and a virtual load acquisition unit (18) that acquires virtual load information generated on the virtual movable units (134s, 136s) obtained by the machining simulation by the simulation unit (14); The simulation system comprises an actual load acquisition unit (16) that acquires actual load information occurring on the movable parts (134, 136) obtained by processing by the actual processing unit (12), and a load information determination unit (22) that compares the virtual load information with the actual load information and determines whether there is a difference between these pieces of information, wherein the simulation unit (14) calculates the virtual load information and comparison point identification data that identifies a comparison point between the virtual load information and the actual load information, the virtual load acquisition unit (18) acquires the virtual load information in association with the comparison point identification data, the actual load acquisition unit (16) acquires the actual load information in association with the comparison point identification data, and the load information determination unit (22) compares the virtual load information with the actual load information based on the comparison point identification data.

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

[0162] (Supplementary Note 3) In the above-described machining load determination system (10), the actual load information includes energy generated in the moving parts (134, 136) when machining the workpiece (W), and the virtual load information includes energy generated in the virtual moving parts (134s, 136s) when machining the virtual workpiece (Ws).

[0163] (Supplementary Note 4) In the above-mentioned machining load determination system (10), the actual load information is contact information indicating whether or not the tool (T) and the workpiece (W) are in contact with each other, and the virtual load information is contact information indicating whether or not the virtual tool (Ts) and the virtual workpiece (Ws) are in contact with each other.

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

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

[0166] (Supplementary Note 7) In the above-mentioned machining load determination system (10), the simulation unit (14) performs the machining simulation based on the operation data including preconditions for the virtual tool (Ts), the virtual workpiece (Ws), and the virtual moving parts (134s, 136s), and when the load information determination unit (22) determines that there is a difference between the virtual load information and the actual load information, it identifies a process in the operation data where there is a difference in information based on the comparison location identification data, and changes the preconditions for the machining simulation.

[0167] (Supplementary Note 8) In the above machining load determination system (10), the actual load information is contact information indicating whether or not the tool (T) and the workpiece (W) are in contact with each other, the virtual load information is contact information indicating whether or not the virtual tool (Ts) and the virtual workpiece (Ws) are in contact with each other, the comparison point specifying data for the actual load information includes position information of the moving parts (134, 136), and the comparison point specifying data for the virtual load information includes position information of the virtual moving parts (134s, 136s), and the simulation unit (14) performs the machining simulation based on the operation data including preconditions for the virtual tool (Ts), the virtual workpiece (Ws), and the virtual moving parts (134s, 136s), If the load information determination unit (22) determines that there is a difference between the virtual load information and the actual load information, the difference between the machine coordinates at which the tool (t) and the workpiece (W) in the actual machining unit (12) come into contact and the machine coordinates at which the virtual tool (Ts) and the virtual workpiece (Ws) come into contact in the simulation unit (14) is calculated, and the preconditions for the virtual tool (Ts) are changed using the difference as a correction amount for the virtual tool (Ts).

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

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

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

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

[0172] REFERENCE SIGNS LIST 10 Machining load determination system 12 Actual machining unit 14 Simulation unit 16 Actual load acquisition unit 18 Virtual load acquisition unit 20 Memory unit 22 Load information determination unit 24 Operation control unit 26 Correction unit 28 Display unit 100 Industrial machinery system 110 Numerical control device 120 Drive unit 130 Machine tool (industrial machinery) 132 Motor 134 Mounting unit (movable unit) 134s Virtual mounting unit (virtual movable unit) 136 Table (movable unit) 136s Virtual table (virtual movable unit) T Tool Ts Virtual tool VS Virtual space W Work (workpiece) Ws Virtual work (virtual workpiece)

Claims

1. An actual processing unit having a movable part provided with a tool or a workpiece, and performing processing of the workpiece by relatively moving the tool and the workpiece based on operation data; In a virtual space including a virtual tool, a virtual workpiece, and a virtual movable part corresponding to the tool, the workpiece, and the movable part respectively, a simulation unit that performs a machining simulation of the virtual workpiece by relatively moving the virtual tool and the virtual workpiece based on the operation data; A virtual load acquisition unit that acquires virtual load information generated on the virtual movable part obtained by the machining simulation by the simulation unit; An actual load acquisition unit that acquires actual load information generated on the movable part obtained by the machining by the actual processing unit; A load information determination unit that compares the virtual load information and the actual load information and determines whether there is a difference between these pieces of information; Comprising: The simulation unit calculates the virtual load information and comparison location specifying data for specifying a comparison location between the virtual load information and the actual load information; The virtual load acquisition unit acquires the virtual load information in association with the comparison location specifying data; The actual load acquisition unit acquires the actual load information in association with the comparison location specifying data; The load information determination unit compares the virtual load information and the actual load information based on the comparison location specifying data; A machining load determination system.

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

3. The actual load information includes energy generated on the movable part when machining the workpiece; The virtual load information includes energy generated on the virtual movable part when machining the virtual workpiece; The machining load determination system according to Claim 1 or 2.

4. The actual load information is contact information indicating whether the tool and the workpiece are in contact; The virtual load information is contact information indicating whether the virtual tool and the virtual workpiece are in contact; The machining load determination system according to Claim 1 or 2.

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

6. When it is determined by the load information determination unit that there is a difference between the virtual load information and the actual load information, in the actual processing unit, at least one of limiting the output for operating the movable part, performing a preset retraction operation of the movable part, or immediately decelerating and stopping the operation of the movable part is performed. The processing load determination system according to claim 1 or 2.

7. The simulation unit performs the processing simulation based on the operation data including the preconditions regarding the virtual tool, the virtual workpiece, and the virtual movable part. When it is determined by the load information determination unit that there is a difference between the virtual load information and the actual load information, in the operation data, a process in which there is a difference in these information is specified based on the comparison location specifying data, and the preconditions of the processing simulation are changed. The processing load determination system according to claim 1 or 2.

8. The actual load information is contact information indicating whether the tool and the workpiece are in contact. The virtual load information is contact information indicating whether the virtual tool and the virtual workpiece are in contact. The comparison location specifying data for the actual load information includes the position information of the movable part. The comparison location specifying data for the virtual load information includes the position information of the virtual movable part. The simulation unit performs the processing simulation based on the operation data including the preconditions regarding the virtual tool, the virtual workpiece, and the virtual movable part. When it is determined by the load information determination unit that there is a difference between the virtual load information and the actual load information, the difference between the machine coordinates where the tool and the workpiece in the actual processing unit are in contact and the machine coordinates where the virtual tool and the virtual workpiece in the simulation unit are in contact is calculated. The preconditions of the virtual tool are changed with the difference as the correction amount of the virtual tool. The processing load determination system according to claim 1 or 2.

9. The simulation unit performs the processing simulation before the actual processing unit operates based on the operation data, and calculates the comparison location specifying data and the virtual load information. The processing load determination system according to claim 1 or 2.

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

11. The processing load determination system according to claim 1 or 2, further comprising a display unit that displays the comparison location specific data determined by the load information determination unit to have a difference between the virtual load information and the actual load information in different display modes according to the difference.

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