Machine tool monitoring system and machine tool monitoring method using the same

Abstract

In a tool condition monitoring system and a tool condition monitoring method using the same, the tool condition monitoring system includes a first shooting unit, a second shooting unit, and a monitoring unit. The first shooting unit acquires a first image of a tool mounted on a tool changer. The second shooting unit acquires a second image of the tool while the tool is being used to process a workpiece. The monitoring unit acquires information about the tool by synchronizing the first image and the second image.

Description

Technology Field

[0001] The present invention relates to a tool condition monitoring system and a tool condition monitoring method using the same, and more specifically, to a tool condition monitoring system and a tool condition monitoring method using the same that monitors the condition of a tool by utilizing both a captured image of a tool mounted on a tool changer and a captured image of a rotating tool during actual processing. Background Technology

[0002] Generally, tools mounted on a tool changer are stored after being used by various users or in various machining environments. Therefore, monitoring and saving the status of each tool mounted and stored in the tool changer is very important in that it allows for the verification of the condition of tools to be used again in the future.

[0003] As a method for monitoring the status of a tool mounted on the above-mentioned tool changer, a common technique involves using a camera to photograph the tool and obtaining tool information from the photographic data, as disclosed in Korean Registered Patent No. 10-2669049.

[0004] In addition, beyond simply monitoring the condition of a specific tool, technology is also being developed to classify tools with similar characteristics or conditions based on photographic information about the tool, as described in Korean Patent Publication No. 10-2020-0010776.

[0005] However, when photographing tools stored in a tool changer using a camera, the space for positioning the camera within the tool changer is relatively insufficient; consequently, the ability to install or move the camera in various ways is limited, and it is common to obtain photographic information regarding only one aspect of the tool. Consequently, the accuracy of the information regarding the condition of the tool is low.

[0006] Furthermore, in the case of relatively long tools, it is difficult to obtain status information for the entire length of the tool using only information captured at a specific location, and similarly, the accuracy of the information regarding the tool's status decreases. Prior art literature

[0007] Republic of Korea Registered Patent No. 10-2669049 Republic of Korea Published Patent No. 10-2020-0010776 The problem to be solved

[0008] Accordingly, the technical problem of the present invention is conceived from this point, and the objective of the present invention is to provide a tool condition monitoring system capable of monitoring the condition of a tool more accurately by obtaining information about the overall shape of the tool through monitoring the condition of the tool using both a captured image of the tool mounted on the tool changer and a captured image of the tool rotating during actual processing.

[0009] In addition, another objective of the present invention is to provide a tool condition monitoring method using the tool condition monitoring system. means of solving the problem

[0010] A tool condition monitoring system according to one embodiment for realizing the purpose of the present invention described above includes a first shooting unit, a second shooting unit, and a monitoring unit. The first shooting unit acquires a first image of a tool mounted on a tool changer. The second shooting unit acquires a second image of the tool while a workpiece is being processed using the tool. The monitoring unit acquires information about the tool by synchronizing the first image and the second image.

[0011] In one embodiment, the first image may be an image of one side of a tool mounted on the tool changer.

[0012] In one embodiment, the second image may be an image of the entire side of the tool according to the rotation of the tool while the workpiece is being processed using the tool.

[0013] In one embodiment, the second image can be obtained from the rotational state at the return point where the tool returns during processing.

[0014] In one embodiment, the second shooting unit controls the shutter speed to be synchronized with the rotational speed (rpm) of the tool, so as to capture an image of the tool when it is stationary.

[0015] In one embodiment, the second shooting unit includes a strobe that operates in synchronization with the rotational speed (rpm) of the tool, so as to be able to capture an image of the tool when it is stationary.

[0016] In one embodiment, the first shooting unit may include a first shooting section positioned on the side of the tool to acquire the first image, and a vertical transfer unit that moves the first shooting section along the longitudinal direction of the tool.

[0017] In one embodiment, the first shooting unit may further include a front light source unit positioned between the first shooting unit and the tool to provide front light to the tool, and a rear light source unit positioned between the front light source unit and the tool to provide rear light to the tool.

[0018] In one embodiment, the monitoring unit may include a first image processing unit that acquires a plurality of first images acquired along the longitudinal direction of the tool in the first shooting unit into a single image, a second image processing unit that acquires a plurality of second images acquired along the rotational direction of the tool in the second shooting unit into a single image, and a synchronization unit that synchronizes the images acquired through the first and second image processing units to acquire a final image of the tool.

[0019] In one embodiment, the monitoring unit further includes a storage unit that stores information of the tool based on a final image of the tool, and the information of the tool may include shape information of the tool and wear or breakage information of the tool.

[0020] A tool condition monitoring method according to one embodiment for realizing another objective of the present invention described above comprises the steps of: selecting a tool mounted on a tool changer; acquiring a first image of the tool using a first capturing unit; performing machining on a workpiece using the tool; acquiring a second image of the tool while the tool is in a machining state using a second capturing unit; and acquiring information of the tool by synchronizing the first image and the second image.

[0021] In one embodiment, in the step of acquiring the second image, the second shooting unit can acquire the second image from the rotational state at the return point where the tool returns during processing.

[0022] In one embodiment, in the step of acquiring the second image, the second shooting unit can repeatedly acquire the second image whenever the tool returns to the return point. Effects of the invention

[0023] According to embodiments of the present invention, by acquiring a first image of a tool mounted on a tool changer and acquiring a second image of the tool in a state where it is processing a workpiece and synchronizing them, information of the tool is acquired, thereby enabling more accurate state information of the tool to be obtained.

[0024] That is, in the case of the first image above, it is merely an image of one side of the tool, so there are limitations in obtaining information about the three-dimensional shape of the tool. Accordingly, since information about the three-dimensional shape of the tool can be obtained through the second image, accurate information about the three-dimensional shape of the tool can be obtained by synchronizing the two images with each other.

[0025] At this time, when acquiring the first image, particularly when the tool is extended relatively long, the first capturing unit can be moved in the up and down direction so that the first image can be acquired over the entire length of the tool, thereby enabling more accurate tool state information to be acquired.

[0026] In addition, when acquiring the second image, since the tool is in a rotating state, in order to acquire an all-around image along the rotation direction, the shutter speed of the second shooting unit is controlled to be synchronized with the rotation speed of the tool, or a strobe is applied that operates in synchronization with the rotation speed of the tool, thereby allowing the image in a stationary state to be accurately acquired. At this time, since the shutter speed and the operation of the strobe can be controlled to acquire all images in the stationary state according to the rotation direction of the tool, the second image can be acquired as an image of the three-dimensional shape of the rotating tool.

[0027] Furthermore, by acquiring the second image whenever it is positioned at a return point or periodically during the process of performing the machining, information on changes in the tool state during the process of the tool performing the machining can also be acquired, thereby enabling more accurate monitoring of the tool state.

[0028] Thus, by synchronizing the first image and the second image, all state information of the tool before, during, and after the start of machining can be obtained, and this information can be stored in a separate storage unit. Through this, when another user performs another machining operation, the machining can be controlled or the tool can be exchanged based on the state information of the tool, thereby enabling the efficiency and optimization of the machining process. Brief explanation of the drawing

[0029] FIG. 1 is a block diagram illustrating a tool condition monitoring system according to one embodiment of the present invention. Figure 2 is a schematic diagram specifically illustrating the tool condition monitoring system of Figure 1. FIG. 3 is a perspective view illustrating the tool changer and the first shooting unit of FIG. 2. FIG. 4a is an example of a first image obtained from a conventional tool changer, and FIG. 4b is an example of a first image obtained through the first shooting unit of FIG. 3. FIG. 5 is a schematic diagram illustrating a second shooting unit in a tool condition monitoring system according to another embodiment of the present invention. Figure 6 is a flowchart illustrating a tool condition monitoring method using the tool condition monitoring system of Figure 1. Figure 7 is a flowchart specifically illustrating the tool condition monitoring method of Figure 6. Specific details for implementing the invention

[0030] The present invention is susceptible to various modifications and may take various forms, and embodiments are to be described in detail in the text. However, this is not intended to limit the invention to the specific disclosed forms, and it should be understood that the invention includes all modifications, equivalents, and substitutions that fall within the spirit and scope of the invention. Similar reference numerals have been used for similar components in the description of each figure. Terms such as "first," "second," etc., may be used to describe various components, but said components should not be limited by said terms.

[0031] The above terms are used solely for the purpose of distinguishing one component from another. The terms used in this application are used merely to describe specific embodiments and are not intended to limit the invention. The singular expression includes the plural expression unless the context clearly indicates otherwise. In this application, terms such as "comprising" or "consisting of" are intended to specify the existence of the features, numbers, steps, actions, components, parts, or combinations thereof described in the specification, and should be understood as not precluding the existence or addition of one or more other features, numbers, steps, actions, components, parts, or combinations thereof.

[0032] Hereinafter, preferred embodiments of the present invention will be described in more detail with reference to the attached drawings.

[0033] FIG. 1 is a block diagram illustrating a tool condition monitoring system according to an embodiment of the present invention. FIG. 2 is a schematic diagram specifically illustrating the tool condition monitoring system of FIG. 1. FIG. 3 is a perspective view illustrating the tool changer and the first imaging unit of FIG. 2.

[0034] Referring to FIGS. 1 to 3, the tool condition monitoring system (10, hereinafter referred to as the monitoring system) according to the present embodiment monitors the tool unit (200) by acquiring and storing the status information of the tool unit (200).

[0035] Generally, the tool unit (200) is stored mounted on the tool changer (100) of a machine tool (not shown), and a specific tool is selected to process a specific workpiece (250). That is, a plurality of tools are mounted and stored in the tool changer (100), and a required tool is selected to perform processing on the workpiece (250).

[0036] The selection of such tools and the execution of workpiece processing are performed through a wide variety of scenarios, and since the processing of the workpiece may be performed by different operators, there is often a lack of continuity in the work. Therefore, the status information of each of the various tools stored in the tool changer (100) needs to be stored in a separate storage unit, and thus, whenever processing is performed, the processing must proceed based on the status information of the tool to be used among the tools stored in the tool changer (100).

[0037] As described above, the status information of each tool mounted and stored in the tool changer (100) must be stored through a separate storage unit, and to do this, the status information of each tool must be obtained in advance.

[0038] Accordingly, the tool condition monitoring system (10) according to the present embodiment acquires and stores condition information for each tool stored in the tool exchange device (100).

[0039] More specifically, the tool condition monitoring system (10) includes a first shooting unit (300), a second shooting unit (400), a monitoring unit (500), and an input / output unit (600).

[0040] The first shooting unit (300) is provided inside the tool changer (100) and obtains information about the tool mounted on the tool changer (100).

[0041] Generally, the tool unit (200) is composed of a tool (210) and a tool holder (220) that fixes the tool (210), as shown in FIG. 2, and the tool (210) is composed of a shank portion (211) and a machining blade (212) formed at the end of the shank portion (211).

[0042] Accordingly, the first shooting unit (300) obtains an image of the tool (210) by shooting the tool (210). At this time, the image of the tool (210) includes not only the image of the shank portion (211) but also the image of the processing blade (212), and corresponds to an image of the entire tool (210).

[0043] Hereinafter, for convenience of explanation, the image of the tool (210) mounted inside the tool changer (100) obtained by the first shooting unit (300) is referred to as the first image.

[0044] Specifically, referring to FIG. 3, the tool changer (100) has tool holders (220) mounted on a base plate, and tools (210) are mounted on each of the tool holders (220), although not shown. Accordingly, the first shooting unit (300) performs shooting on each of the tools (210) mounted on the tool changer (100).

[0045] Meanwhile, the tool selected for processing the workpiece (250) in the tool changer (100) is moved to a location where the first imaging unit (300) is provided, and then moved out of the tool changer (100) for subsequent processing. That is, the first imaging unit (300) is positioned at a location before the tool selected for processing the workpiece (250) is moved out of the tool changer (100), and performs imaging of the tool.

[0046] Through the imaging of the first imaging unit (300) above, the tool performing the processing on the workpiece (250) can be identified, and through this identification, the status information of the tool performing the processing can be immediately checked.

[0047] Furthermore, even when the processing of the above workpiece (250) is finished, the tool returns to the corresponding position, so the first shooting unit (300) can take a picture of the returned tool to obtain information on the state of the tool after the processing is performed.

[0048] That is, since the state information of the tool before and after the processing can be obtained at the same location through the first shooting unit (300), information about the state of the tool being deformed through processing can be obtained, and the final state information of the tool can be stored in the storage unit (550). Accordingly, the information about the tool stored in this way allows the state information of the tool to be checked in advance before processing in subsequent processing using the tool, as previously explained.

[0049] Meanwhile, the first shooting unit (300) includes a first shooting section (310), a vertical transfer unit (320), a horizontal transfer unit (330), a front light source section (340), and a rear light source section (350).

[0050] At this time, the front light source unit (340) and the rear light source unit (350) are respectively located on both sides centered on the tool, with the front light source unit (340) located inside the tool changer (100) centered on the tool, and the rear light source unit (350) located outside the tool changer (100) centered on the tool. Although the tool is not shown in FIG. 3, the tool is fixed on the tool holder (220) as previously explained.

[0051] Each of the above front and rear light source units (340, 350) provides light toward the tool, thereby providing the necessary light when taking a picture of the tool through the first shooting unit (310). That is, since the interior of the tool changer (100) is a space where no separate light is provided, when taking a picture of the tool through the first shooting unit (310), it may be difficult to identify the tool in the image of the tool. Accordingly, by providing light to the tool through the above front and rear light source units (340, 350), the tool can be identified more effectively in the first image of the tool.

[0052] FIG. 4a is an example of a first image obtained from a conventional tool changer, and FIG. 4b is an example of a first image obtained through the first shooting unit of FIG. 3.

[0053] That is, as shown in FIG. 4a, when shooting is performed inside a conventional tool changer, generally only a rear light source (350) is provided, and the first image obtained is merely a black and white image, so there is a limitation in that it is difficult to accurately recognize the shape of the tool.

[0054] In contrast, as shown in FIG. 4b, when photographing a tool (210) located inside the tool changer (100) through the first shooting unit (300) according to the present embodiment, since the shooting is performed by receiving light sources from both the rear light source unit (350) and the front light source unit (340), the first image obtained therefrom can be relatively contoured and accurately identified in terms of its shape.

[0055] Meanwhile, the first imaging unit (310) is provided on the inner side of the front light source unit (340), that is, on the side opposite to the direction facing the tool, to acquire a first image of the tool. Generally, in the case of the tool changer (100), the tool is removed to the outside in a manner where a circular base plate rotates, and there is no separate space other than the space where the tool is mounted. Therefore, in the tool changer (100), the first imaging unit (310) must be located inside the circumferential side where the tool is mounted on the circular base plate, and thereby, the tool changer (100) can be manufactured to minimize its overall volume while utilizing the space of the tool changer (100) more effectively.

[0056] The horizontal transfer unit (330) extends along a first direction (X) on the circular base plate and includes a horizontal frame (331) and a horizontal guide part (332). At this time, the horizontal guide part (332) extends along the first direction (X), and the horizontal frame (331) is a frame that fixes the horizontal guide part (332).

[0057] The first shooting unit (310) is moved along the horizontal guide unit (332) along the first direction (X). Thus, the first shooting unit (310) is moved in the first direction (X) to acquire the first image of the tool at a more appropriate position.

[0058] The vertical transfer unit (320) extends along a third direction (Z) perpendicular to a first direction (X) on the circular base plate and includes a vertical frame (321) and a vertical guide part (322). At this time, the vertical guide part (322) extends along the third direction (Z), and the vertical frame (321) is a frame that fixes the vertical guide part (322). Meanwhile, as illustrated, the third direction (Z) corresponds to the vertical direction in which the tool extends.

[0059] The first shooting unit (310) is moved along the vertical guide unit (322) along the third direction (Z). Thus, the first shooting unit (310) is moved in the third direction (Z) to acquire the first image of the tool at a more appropriate position.

[0060] Generally, if the length of the tool is relatively small, the first image can be obtained by taking a single shot of the entire tool through the first shooting unit (310).

[0061] However, if the length of the tool is increased, it may be difficult to obtain a first image of the entire tool at once through a single shot by the first shooting unit (310). Accordingly, in the present embodiment, the first shooting unit (310) is moved in the third direction (Z), multiple shots are taken of the tool, and each image obtained from the multiple shots is processed to obtain a first image of the entire tool.

[0062] Image processing that combines multiple images of the same tool in the third direction (Z) captured by the first shooting unit (310) into a single image can be implemented through the first image processing unit (520) described later.

[0063] Meanwhile, the first shooting unit (310) may be, for example, a vision camera.

[0064] Thus, the first shooting unit (310) in the present embodiment can more accurately acquire a first image of the entire tool regardless of the length of the tool, and thereby can more accurately acquire state information about the tool.

[0065] As described above, the first shooting unit (300) acquires a first image with the tool mounted on the tool changer (100).

[0066] In contrast, the second shooting unit (400) acquires an image of the tool while the tool is positioned outside the tool changer (100) and performing processing on the workpiece (250). At this time, the image acquired while processing is being performed is named the second image for convenience of explanation.

[0067] Specifically, the second shooting unit (400) includes a second shooting section (410), and the second shooting section (410) may also be a vision camera. The second shooting section (410) is positioned adjacent to the tool performing the processing.

[0068] Generally, the tool (210) returns to a predetermined return point at regular intervals along a certain machining path or at regular intervals while performing machining on the workpiece (250). Additionally, even when the tool (210) returns to the return point, the tool (210) maintains a state of being rotated at a given rotational speed (rpm).

[0069] Accordingly, in this embodiment, the second shooting unit (410) is positioned adjacent to the return point, so that when the tool (210) rotates while in a state of returning to the return point, the second image is obtained through shooting the tool (210).

[0070] However, since the tool (210) is in a state of being rotated at a predetermined number of rotations, the second shooting unit (410) must acquire the second image by taking into account the number of rotations of the rotating tool (210).

[0071] That is, information regarding the current rotational speed of the tool is provided to the second shooting unit (400) through a control unit (700) that controls the rotation and movement path of the tool (210). Thus, the second shooting unit (410) controls the shutter speed to be synchronized with the rotational speed of the tool (210) and performs a shot of the tool (210). Through this, even if the tool (210) is rotated, the shutter speed operates in synchronization with the rotational speed, so an image of the tool (210) in a stationary state can be obtained as the second image.

[0072] Meanwhile, when acquiring an image of the tool (210) in a stationary state through the second shooting unit (410), only an image of one side of the tool (210) is acquired. That is, if the shutter speed of the second shooting unit (410) is maintained constant, a stationary image of the same side is always acquired when the rotation speed of the tool (210) is constant.

[0073] Accordingly, the control unit (700) synchronizes the shutter speed of the second shooting unit (410) with the rotation speed of the tool (210), and by varying the synchronization time, images of other sides of the tool (210) can also be obtained through the second shooting unit (410). Thus, when the tool (210) rotates at a constant rotation speed, images of different sides of the tool (210) can be obtained by controlling the shutter speed differently. Through this, so-called all-around images of the entire side of the tool (210) can be obtained.

[0074] Accordingly, by combining images of each of the sides of the tool (210) through the second image processing unit (530) described later, an all-around image of the entire side of the tool (210) can be obtained as the second image.

[0075] In the case of the first shooting unit (310) mentioned above, the tool (210) is in a stationary state without rotating, and the first shooting unit (310) is also fixed at a specific position; therefore, the first image obtained through the first shooting unit (310) is limited to a side image following a specific direction of the tool (210).

[0076] In contrast, in the case of the second shooting unit (410), the shutter speed of the second shooting unit (410) is controlled by the control unit (700) based on the rotational speed information of the tool (210), thereby allowing an all-around image of the entire side of the tool (210) to be obtained as the second image.

[0077] In addition, in the case of the second shooting unit (410), a second image of the tool (210) can be acquired whenever the tool (210) returns to the return point, so that the change in the state of the tool can be periodically acquired during the process of the tool (210) performing processing on the workpiece (250).

[0078] Accordingly, the status information of the tool (210) according to the processing time can be obtained more accurately.

[0079] The monitoring unit (500) obtains status information of the tool based on the shooting results of the first and second shooting units (310, 410). At this time, the status information of the tool includes all information that can be obtained through images, such as shape information of the tool, wear status information of the tool, and damage status information of the tool.

[0080] Specifically, the monitoring unit (500) includes a tool information acquisition unit (510), a first image processing unit (520), a second image processing unit (530), a synchronization unit (540), and a storage unit (550).

[0081] The tool information acquisition unit (510) acquires information about a tool selected from the tool changer (100), and the tool status information is stored through subsequent image synchronization, etc., for the selected tool.

[0082] Of course, a separate tool information acquisition unit (510) is omitted, and based on the first image of the tool captured through the first shooting unit (310) as described above, the selected tool can be identified, and through this, tool status information can be stored through subsequent image synchronization for the selected tool.

[0083] As previously described, the first image processing unit (520) acquires the first image based on images captured by the first shooting unit (310). That is, the first shooting unit (310) acquires a plurality of images while moving along the third direction (Z) with respect to the tool (210) extending in the third direction (Z). Accordingly, regarding the plurality of images of the tool (210) acquired while moving along the third direction (Z), the first image processing unit (520) integrates the images to acquire a single first image of the tool (210).

[0084] Of course, if the length of the tool (210) is relatively short and the entire image of the tool (210) can be obtained with only one image, the first image processing unit (520) may not need to perform separate image synthesis.

[0085] Thus, the first image obtained from the first image processing unit (520) is provided to the synchronization unit (540). Meanwhile, as previously explained, the first image obtained from the first image processing unit (520) corresponds to an image of one side of the tool (210).

[0086] As previously described, the second image processing unit (530) acquires the second image based on images captured by the second shooting unit (410). That is, the second shooting unit (410) acquires multiple images along the side of the tool (210) through shutter speed control synchronized with the rotation speed of the tool (210). Accordingly, regarding the multiple images acquired along the sides of the tool (210), the second image processing unit (530) integrates the images to acquire a single second image of the tool (210). At this time, the second image may be a three-dimensional image of the tool (210). That is, all-around images of the sides of the tool (210) can be combined to finally acquire a three-dimensional image of the entire tool (210) as the second image.

[0087] Thus, the second image obtained from the second image processing unit (530) is provided to the synchronization unit (540).

[0088] The synchronization unit (540) synchronizes the first image of one side of the tool (210) obtained through the first image processing unit (520) with the second image of the entire side of the tool (210) obtained through the second image processing unit (530) to finally obtain an image of the tool (210). At this time, synchronizing the first and second images means integrating the two images by modifying them to have the same size and the same ratio based on the position and shape of the tool for each image, and various image processing methods may be applied. Thus, the first and second images can be integrated into a single image.

[0089] Since the first image is merely an image of one side of the tool (210), it is synchronized with the second image to obtain a final image of the entire image of the tool (210), and the entire image of the tool (210) obtained through this may be a three-dimensional image.

[0090] Meanwhile, the second image may be an image of the tool (210) in a state where rotation has started at the return point before processing the workpiece (250), and if the second image before processing and the first image are synchronized with each other to obtain a single final image, the image will contain state information regarding the tool (210) before processing begins.

[0091] Alternatively, the second image may be an image of the tool (210) returning to the return point and rotating after performing a predetermined machining on the workpiece (250). In this case, if the first image and the second image are synchronized, both the state information of the tool (210) before machining and the state information of the tool (210) after performing the predetermined machining are included, thereby including information regarding the change in the state of the tool before and after machining.

[0092] Ultimately, the first and second images are synchronized with each other through the synchronization unit (540), and the synchronized images are stored in the storage unit (550). The information stored through the storage unit (550) may be state information of the tool (210) in its initial state before processing, or information regarding the state change of the tool (210) whenever processing is performed.

[0093] Furthermore, after all processing of the processing unit (250) is performed using the tool (210), the tool (210) is returned to the tool exchange device (100), and the first image can be obtained again through the first shooting unit (310) for the tool returned to the tool exchange device (100).

[0094] Thus, regarding the above tool (210), information on the state of the tool in the initial state before processing is performed, information on the state (change) of the tool for each processing step, and information on the state of the tool in the final state after processing is performed can all be stored in the storage unit (550).

[0095] The above input / output unit (600) outputs information regarding the tool status stored in the storage unit (550) to the outside, and may include a separate display unit (not shown) for outputting the information. Additionally, an input requiring verification of information from the outside may be performed through the above input / output unit (600), and at this time, the above input / output unit (600) extracts tool status information corresponding to the input information from the storage unit (550) and provides it to the outside.

[0096] Additionally, when a user selects a specific tool to perform a specific processing operation, the input / output unit (600) can extract status information for the selected tool from the storage unit (550) and display it to the user.

[0097] That is, based on the information stored in the storage unit (550), the user can not only check the state information of the tool that has changed through the processing, but also predict the final state information of the tool by considering the state information of the tool to be used and the expected processing process before starting the next processing.

[0098] FIG. 5 is a schematic diagram illustrating a second shooting unit in a tool condition monitoring system according to another embodiment of the present invention.

[0099] In the case of the tool condition monitoring system according to the present embodiment, except that the second shooting unit (401) further includes a strobe (420), it is substantially the same as the tool condition monitoring system (10) described with reference to FIGS. 1 to 3, so the same reference numbers are used for the same components and redundant descriptions are omitted.

[0100] Referring to FIG. 5, in the monitoring system according to the present embodiment, the second shooting unit (401) further includes the strobe (420) in addition to the second shooting unit (410).

[0101] The above strobe (420) is controlled by the control unit (700) to operate at a certain period or at a specific time and to provide light, so-called strobe light. At this time, the control unit (700) controls the operation of the strobe (420) based on information regarding the rotational speed of the tool (210). Thus, when the second shooting unit (410) performs shooting at the time when the strobe (420) is operating, that is, when shooting is performed in synchronization, an image of the tool (210) can be obtained.

[0102] That is, since the control unit (700) knows the rotational speed information of the tool (210) in advance, it can know the side information of the tool (210) that is captured when shooting is performed at the location where the second shooting unit (410) is located.

[0103] Accordingly, by controlling the strobe (420) to operate at a specific time, an image of a specific side of the tool (210) can be obtained. Through this, so-called all-round images of all sides of the tool (210) can be obtained.

[0104] This can yield the same result as obtaining an all-around image of the entire sides of the tool (210) by controlling the shutter speed of the aforementioned first shooting unit (410). Accordingly, as described above, through the monitoring unit (500), tool status information at each stage of the tool (210), namely the initial stage, each stage during processing, and the final stage, can be obtained in the same way.

[0105] Hereinafter, a tool condition monitoring method (hereinafter referred to as the monitoring method) using the tool condition monitoring system (10) of FIG. 1 will be described. However, in the case of the monitoring method of FIG. 5, the second image obtained is substantially the same except that the operation of the strobe (420) is controlled by the control unit (700), so it is substantially the same as the monitoring method using the monitoring system (10) of FIG. 1 below.

[0106] FIG. 6 is a flowchart illustrating a tool condition monitoring method using the tool condition monitoring system of FIG. 1. FIG. 7 is a flowchart specifically illustrating the tool condition monitoring method of FIG. 6.

[0107] Referring to FIGS. 6 and FIGS. 7, in the monitoring method, first, a tool that performs machining is selected from among the tools mounted on the tool changer (100) (step S10). Of course, a tool that is not necessarily a tool that performs machining may be selected to obtain status information.

[0108] Afterward, a first image is obtained for the selected tool using the first shooting unit (300) (step S20). At this time, the image obtained through the first shooting unit (300) is an image of the tool mounted on the tool changer (100).

[0109] Meanwhile, if the selected tool is relatively long and it is difficult to obtain a first image as a single image, the first shooting unit (310) can be moved in the third direction (Z) to obtain multiple images of the tool (step S21), and the images obtained in this way are integrated through the first image processing unit (520) to obtain a single first image, i.e., a first integrated image (step S22).

[0110] Afterward, machining is performed on the workpiece with the selected tool (step S30). Additionally, when the tool is located at a return point during the process of machining the workpiece, a second image of the tool is acquired using the second shooting unit (400) (step S40).

[0111] More specifically, when acquiring a second image of the selected tool, the second image can be acquired using the second shooting unit (400) when the tool starts rotating at the return point before starting the processing. That is, when the tool starts rotating at a first rotational speed from the initial position defined as the return point (step S31), a second image is acquired for the tool rotating at the first rotational speed (step S41). At this time, the first rotational speed of the tool and the shutter speed of the second shooting unit (410) are synchronized with each other through the control unit (700) to acquire the second image.

[0112] Meanwhile, as previously explained, the second image includes multiple images obtained for all sides of the tool, so the multiple images obtained are integrated through the second image processing unit (530) to obtain a single second image, i.e., a second integrated image (step S42). At this time, the integrated second image may be a three-dimensional image of the tool, as previously explained.

[0113] The step of acquiring the second integrated image can be acquired whenever the tool is positioned at the return point, or whenever the tool is positioned at the return point. That is, as shown in FIG. 7, after the tool has performed machining at the first rotational speed (step S32), when it is positioned at the return point (initial position) to perform machining at the second rotational speed different from the first rotational speed (step S33), another second integrated image can be acquired through the second shooting unit (400).

[0114] That is, a second image is obtained through the second shooting unit (410) controlled by a shutter speed synchronized with the second rotation speed (step S43), and the second image is processed in the second image processing unit (530) to obtain an integrated second image (at this time, for distinction, it is described as a third integrated image in the drawing) (step S44).

[0115] As described above, when the second image is obtained for each rotational number or for each return point, the synchronization unit (540) synchronizes the first image and the second image to obtain a final image (step S50).

[0116] That is, as shown in FIG. 7, the synchronization unit (540) integrates a first image obtained for a specific side at a stopped position in the tool changer (100) and a second image obtained for the entire side of a rotating tool when returning to the return point (at this time, it is not necessary to rotate every return point when having different rotational speeds, and the rotation to the return point can be varied considering the machining operation, and it is sufficient to take a picture while in the state of returning to the return point). At this time, in the case of the second image, if it is taken every time it returns to the return point, a second, third, ..., Nth integrated image can be obtained (the number of times taken by the second shooting unit is N-1 times).

[0117] Thus, the synchronization unit (540) synchronizes the first image with the second to Nth integrated images to obtain a final integrated image. At this time, the final integrated image does not need to be integrated into a single image and refers to an image capable of obtaining state information of the tool. That is, an image of the tool in an initial state, an image of the tool at each stage of processing, and an image of the tool after all processing is completed can be obtained in a series of sequences to obtain the final integrated image, and these images can be merged together to obtain a single image as the final integrated image.

[0118] Furthermore, information regarding the final integrated image stored in this way is stored in the storage unit (550) (step S60), and through this, the status information of the tool can be obtained.

[0119] According to the embodiments of the present invention as described above, by acquiring a first image of a tool mounted on a tool changer and acquiring a second image of the tool in a state where it is processing a workpiece and synchronizing them, information of the tool is acquired, thereby enabling more accurate state information of the tool to be obtained.

[0120] That is, in the case of the first image above, it is merely an image of one side of the tool, so there are limitations in obtaining information about the three-dimensional shape of the tool. Accordingly, since information about the three-dimensional shape of the tool can be obtained through the second image, accurate information about the three-dimensional shape of the tool can be obtained by synchronizing the two images with each other.

[0121] At this time, when acquiring the first image, particularly when the tool is extended relatively long, the first capturing unit can be moved in the up and down direction so that the first image can be acquired over the entire length of the tool, thereby enabling more accurate tool state information to be acquired.

[0122] In addition, when acquiring the second image, since the tool is in a rotating state, in order to acquire an all-around image along the rotation direction, the shutter speed of the second shooting unit is controlled to be synchronized with the rotation speed of the tool, or a strobe is applied that operates in synchronization with the rotation speed of the tool, thereby allowing the image in a stationary state to be accurately acquired. At this time, since the shutter speed and the operation of the strobe can be controlled to acquire all images in the stationary state according to the rotation direction of the tool, the second image can be acquired as an image of the three-dimensional shape of the rotating tool.

[0123] Furthermore, by acquiring the second image whenever it is positioned at a return point or periodically during the process of performing the machining, information on changes in the tool state during the process of the tool performing the machining can also be acquired, thereby enabling more accurate monitoring of the tool state.

[0124] Thus, by synchronizing the first image and the second image, all state information of the tool before, during, and after the start of machining can be obtained, and this information can be stored in a separate storage unit. Through this, when another user performs another machining operation, the machining can be controlled or the tool can be exchanged based on the state information of the tool, thereby enabling the efficiency and optimization of the machining process.

[0125] Although the present invention has been described above with reference to preferred embodiments, those skilled in the art will understand that various modifications and changes can be made to the invention without departing from the spirit and scope of the invention as set forth in the following claims. Explanation of the symbols

[0126] 10: Tool Condition Monitoring System 100 : Tool changer 200 : Tool unit 300: 1st Filming Unit 310: 1st Filming Section 320: Vertical transfer unit 340: Front light source unit 350: Rear light source unit 400, 401: Second shooting unit 410: 2nd Camera Unit 420: Strobe 500: Monitoring Unit 510: Tool Information Acquisition Unit 520: 1st image processing unit 530: 2nd image processing unit 540 : Synchronization unit 550 : Storage unit 600: Input / Output Unit 700: Control Unit

Claims

Claim 1 A tool condition monitoring system comprising: a first shooting unit for acquiring a first image of a tool mounted on a tool changer; a second shooting unit for acquiring a second image of the tool while processing a workpiece using the tool; and a monitoring unit for acquiring information of the tool by synchronizing the first image and the second image, wherein the monitoring unit comprises: a first image processing unit for acquiring a plurality of first images acquired from the first shooting unit into a single image; a second image processing unit for acquiring a plurality of second images acquired from the second shooting unit into a single image; and a synchronization unit for acquiring a final image of the tool by synchronizing the images acquired through the first and second image processing units. Claim 2 A tool condition monitoring system according to claim 1, wherein the first image is an image of one side of a tool mounted on the tool changer. Claim 3 A tool condition monitoring system according to claim 2, wherein the second image is an image of the entire side of the tool according to the rotation of the tool while the tool is used to process a workpiece. Claim 4 A tool condition monitoring system according to claim 3, wherein the second image is obtained from the rotational state at the return point where the tool returns during processing. Claim 5 A tool condition monitoring system according to claim 3, wherein the second shooting unit controls the shutter speed to be synchronized with the rotational speed (rpm) of the tool, thereby capturing an image of the tool in a stationary state. Claim 6 A tool condition monitoring system according to claim 3, wherein the second shooting unit includes a strobe that operates in synchronization with the rotational speed (rpm) of the tool, and captures an image of the tool when it is in a stationary state. Claim 7 A tool condition monitoring system according to claim 1, wherein the first shooting unit comprises: a first shooting section positioned on the side of the tool to acquire the first image; and a vertical transfer unit that moves the first shooting section along the longitudinal direction of the tool. Claim 8 A tool condition monitoring system according to claim 7, wherein the first shooting unit further comprises: a front light source unit positioned between the first shooting unit and the tool to provide front light to the tool; and a rear light source unit positioned between the front light source unit and the tool to provide rear light to the tool. Claim 9 A tool condition monitoring system according to claim 1, wherein the first image processing unit acquires a plurality of first images acquired along the longitudinal direction of the tool in the first shooting unit into a single image, and the second image processing unit acquires a plurality of second images acquired along the rotational direction of the tool in the second shooting unit into a single image. Claim 10 A tool condition monitoring system according to claim 9, wherein the monitoring unit further comprises a storage unit that stores information of the tool based on a final image of the tool, and the information of the tool includes shape information of the tool and information on wear or breakage of the tool. Claim 11 A tool condition monitoring method comprising: a step of selecting a tool mounted on a tool changer; a step of acquiring a first image of the tool using a first shooting unit; a step of performing machining on a workpiece using the tool; a step of acquiring a second image of the tool while the tool is in a machining state using a second shooting unit; and a step of acquiring information of the tool by synchronizing the first image and the second image, wherein in the step of acquiring information of the tool, a plurality of first images are acquired as a single image and a plurality of second images are acquired as a single image, and then the acquired images are synchronized to acquire a final image of the tool. Claim 12 A tool condition monitoring method according to claim 11, wherein, in the step of acquiring the second image, the second shooting unit acquires the second image from the rotational state at the return point where the tool returns during processing. Claim 13 A tool condition monitoring method according to claim 12, wherein in the step of acquiring the second image, the second shooting unit repeatedly acquires the second image whenever the tool returns to the return point.

Images