System, and method for controlling machine tool

Abstract

This machine tool: acquires sensing data at a prescribed timing from among sensing data held by a state-monitoring device; derives a threshold value corresponding to the sensing data by using at least some of the sensing data; displays a display screen image indicating a transition in a signal value of the sensing data; identifies, as a replacement target when the signal value of the acquired sensing data exceeds the threshold value, a replaceable component of the machine tool, which is defined in advance as a measurement target being measured by a sensor for acquiring the sensing data; and displays information pertaining to the replaceable component in the display screen image.

Description

System and machine tool control method - Patents.com

[0001] The present invention relates to a system and a method for controlling a machine tool.

[0002] Conventionally, machine tools have been used to process various materials, etc., and the state of the machine tools has been appropriately monitored during use. Since various parts equipped on machine tools include parts that are worn with use, proper monitoring of changes in their state due to the degree of wear and tear can enable normal operation to be performed and continued.

[0003] For example, Patent Document 1 discloses a configuration for monitoring an abnormality in a device based on sensing data and saving the sensing data when an abnormality is detected, while Patent Document 2 discloses a configuration for acquiring data from a machine tool.

[0004] International Publication No. 2020 / 183730 Japanese Patent No. 6638370

[0005] When a status change is detected through the above-described machine tool monitoring, it is necessary to prompt the user of the machine tool to take a predetermined action in response to the status change. For example, components of the machine tool may wear out during use. When a part wears out, it is desirable to replace the part early to ensure more appropriate operation. Such status changes due to part wear are determined based on sensing data from sensors, as in Patent Document 1. However, conventional methods have not adequately considered not only the presentation of parts to be replaced, but also inventory management and ordering processing based on the number and type of parts involved. Identifying the part causing the status change and individually determining which parts should be replaced places a heavy burden on the user. Furthermore, individually checking each part and ordering processing is time-consuming. Furthermore, when a part is replaced, conventional methods have not adequately considered how to handle the sensing data measured up to that point and how to handle thresholds for determining the status of the part based on the sensing data before and after replacement.

[0006] In view of the above problems, an object of the present invention is to improve the convenience of part replacement and data management when using a mechanical device having replaceable parts.

[0007] In order to solve the above problems, the present invention has the following configuration: That is, a system including a machine tool including a replaceable part, a sensor that measures the machine tool, and a condition monitoring device that manages sensing data measured by the sensor, wherein the machine tool has: acquisition means that acquires sensing data at a predetermined timing from sensing data held in the condition monitoring device, derivation means that derives a threshold value corresponding to the sensing data using at least a part of the sensing data acquired by the acquisition means, display control means that displays a display screen showing changes in signal values ​​of the sensing data acquired by the acquisition means, and identification means that, when the signal value of the sensing data acquired by the acquisition means exceeds the threshold value, identifies a replaceable part of the machine tool that has been predefined as a measurement target by the sensor that acquired the sensing data as a part to be replaced, and when a replaceable part is identified by the identification means, the display control means displays information about the replaceable part on the display screen.

[0008] Another aspect of the present invention has the following configuration: A method for controlling a machine tool including a replaceable part, comprising: an acquisition step of acquiring sensing data at a predetermined timing from sensing data held in a condition monitoring device that manages sensing data resulting from measurements made on the machine tool by sensors; a derivation step of deriving a threshold value corresponding to the sensing data using at least a part of the sensing data acquired in the acquisition step; a display control step of displaying a display screen showing transitions in signal values ​​of the sensing data acquired in the acquisition step; and an identification step of identifying, when the signal value of the sensing data acquired in the acquisition step exceeds the threshold value, a replaceable part of the machine tool that has been defined in advance as a measurement target by the sensor that acquired the sensing data, as a part to be replaced; and, when a replaceable part is identified in the identification step, the display control step causes information of the replaceable part to be displayed on the display screen.

[0009] The present invention makes it possible to improve the convenience of part replacement and data management when using a mechanical device having replaceable parts.

[0010] 1 is a block diagram showing an example of the configuration of a condition monitoring system according to an embodiment of the present invention. 2 is a diagram for explaining data acquisition according to an embodiment of the present invention. 3 is a diagram for explaining trend data according to an embodiment of the present invention. 4 is a diagram for explaining an example of the configuration of a UI screen of a machine tool according to an embodiment of the present invention. 5 is a diagram for explaining data archiving according to an embodiment of the present invention. 6 is a diagram for explaining data archiving according to an embodiment of the present invention. 7 is a sequence diagram showing a processing flow according to an embodiment of the present invention. 8 is a sequence diagram showing a flow of UI generation processing according to an embodiment of the present invention. 9 is a block diagram showing an example of the configuration of a condition monitoring system according to another embodiment of the present invention. 10 is a diagram for explaining an example of the configuration of a UI screen of a machine tool according to another embodiment of the present invention.

[0011] Hereinafter, embodiments for carrying out the present invention will be described with reference to the drawings. Note that the embodiment described below is one embodiment for explaining the present invention and is not intended to be interpreted as limiting the present invention. Furthermore, not all of the configurations described in each embodiment are necessarily essential configurations for solving the problems of the present invention. Furthermore, in each drawing, the same components are assigned the same reference numerals to indicate corresponding relationships.

[0012] Although the present invention will be described with reference to a machine tool as an example of application, the present invention is not limited to this example and can be applied to any device in general that includes replaceable parts, such as those described below, that are subject to wear and tear as they are used.

[0013] <First embodiment> A first embodiment of the present invention will be described below. In the system according to this embodiment, a machine tool 10, a condition monitoring device 40, a sensor 50, an inventory management system 60, and an external system 70 are connected to each other so that they can communicate with each other. Note that the installation locations of each device are not particularly limited, but it is preferable that at least the machine tool 10, the condition monitoring device 40, and the sensor 50 are installed at the same base or the like.

[0014] The machine tool 10 is a device capable of performing various machining operations on an object to be machined. The machine tool 10 includes a mechanical unit 20 and a control device 30. The mechanical unit 20 is a component used to machine an object, such as a feed mechanism, a spindle, or ancillary equipment, or, in the case of an injection molding machine, an injection shaft or a die clamping shaft. The mechanical unit 20 is composed of multiple components, such as replaceable bearings, ball screws, and linear guide components. This configuration enables the machine tool 10 to perform operations such as cutting, grinding, shearing, forging, and rolling. In this embodiment, replaceable components among the various components constituting the mechanical unit 20 are described as replaceable components 21. The replaceable components 21 correspond to components that are subject to wear and tear during operation of the mechanical unit 20. Examples of replaceable components 21 include, but are not limited to, bearings, ball screws, linear guide components, motors, and spindles. The operation of the mechanical unit 20 of the machine tool 10 may be performed under the control of the control device 30 or manually by a user.

[0015] The control device 30 includes a processing unit 31, a storage unit 32, a UI (User Interface) unit 33, and a communication unit 34. The processing unit 31 may be configured from a CPU (Central Processing Unit), an MPU (Micro Processing Unit), a DSP (Digital Single Processor), a GPU (Graphical Processing Unit), a GPGPU (General-Purpose Computing on Graphics Processing Units), a dedicated circuit, or the like. The memory unit 32 is composed of volatile and non-volatile storage media such as a hard disk drive (HDD), a read-only memory (ROM), or a random access memory (RAM), and is capable of inputting, outputting, and recording various information based on requests from the processing unit 31.

[0016] The UI unit 33 receives operations from the user and displays a UI screen, which will be described later. The UI unit 33 may be configured, for example, as a touch panel display in which an operation unit and a display unit are integrated. The communication unit 34 is a network interface for connection to an external device, and controls the transmission and reception of data with, for example, the status monitoring device 40 and the inventory management system 60. The communication by the communication unit 34 may use any combination of communication standards, such as wired and wireless, and is not particularly limited.

[0017] The condition monitoring device 40 stores and manages the sensing data continuously transmitted from the sensor 50 in a cache (not shown) or the like, and provides the data to the machine tool 10 when a request is received from the control device 30 of the machine tool 10 or when a specified event occurs.

[0018] The sensors 50 are installed around the mechanical parts 20 (particularly the replaceable parts 21) of the machine tool 10 and measure them to acquire sensing data. The acquired sensing data is continuously provided to the condition monitoring device 40. Examples of the sensors 50 include, but are not limited to, acceleration sensors, rotation sensors, vibration sensors, temperature sensors, and current sensors. The number of sensors 50 is not limited to one type, and multiple types may be provided depending on the measurement targets in the machine tool 10, or one type of sensor may be provided in multiple locations depending on the number of measurement targets.

[0019] In the example of Fig. 1, the condition monitoring device 40 and the sensor 50 are shown in a one-to-one relationship, but they may be configured in a one-to-multiple or multiple-to-multiple relationship. Also, in the example of Fig. 1, only one machine tool 10 is shown, but multiple machines may be provided. In this case, multiple machine tools may be associated with one condition monitoring device. Also, while the condition monitoring device 40 and the sensor 50 are shown as separate components from the machine tool 10, they may be configured as an integrated unit.

[0020] The inventory management system 60 is a system for managing the inventory of replaceable parts 21 of the mechanical unit 20 provided in the machine tool 10. Furthermore, the inventory management system 60 processes orders for replaceable parts from an external system 70 based on instructions from the machine tool 10. The inventory management system 60 may be, for example, a server configured on a network (not shown) such as the Internet. The inventory management system 60 queries the external system 70 at a predetermined timing to obtain information related to the inventory and delivery dates of the replaceable parts 21.

[0021] The external system 70 is a system that performs a series of processes, such as providing information about the replaceable parts 21, accepting orders, and shipping products, based on requests from the inventory management system 60. The external system 70 is, for example, a system provided by a seller or manufacturer of the replaceable parts 21. While one external system 70 is illustrated in FIG. 1 , multiple external systems 70 may be provided depending on the types of replaceable parts 21, the number of providers, and the like, and the inventory management system 60 may be able to link with these external systems.

[0022] [Data Example] Data handling according to this embodiment will be described with reference to FIGS. 2 and 3. FIG.

[0023] Figure 2 is a diagram for explaining the data transmitted from the condition monitoring device 40 to the control device 30 of the machine tool 10. In the three graphs shown in Figure 2, the horizontal axis indicates time t, and each corresponds to another. The vertical axis of the upper graph indicates the signal value of the sensing data measured by the sensor 50. The middle graph indicates the control signal transmitted from the control device 30 of the machine tool 10 to the condition monitoring device 40. The vertical axis of the lower graph indicates the signal value of the sensing data transmitted from the condition monitoring device 40 to the control device 30 of the machine tool 10.

[0024] In the upper graph, a waveform 201 indicates sensing data measured by the sensor 50. The condition monitoring device 40 continuously receives the sensing data measured by the sensor 50 and stores it in a storage unit such as a cache (not shown). In addition, a threshold value th is set in advance for the sensing data, and the condition monitoring device 40 stores information related to the threshold value th so that it can be referenced.

[0025] As indicated by control signal 202, condition monitoring device 40 receives a control signal that turns ON at a predetermined timing that is separately instructed in advance from control device 30 of machine tool 10. In the example of FIG. 2, control signal 202 is shown to turn ON at time t1. Condition monitoring device 40 extracts sensing data for a predetermined period P1 from time t1 when control signal 202 turns ON from the sensing data indicated by waveform 201, and transmits the extracted sensing data to machine tool 10. In the example of FIG. 2, sensing data indicated by waveform 203 is extracted and transmitted to machine tool 10. When sensing data is acquired due to a control signal, sensing data may be acquired under predetermined measurement conditions. The predetermined measurement conditions here may be a measurement time, a sampling frequency, etc., specified by control device 30, or may be predetermined.

[0026] Furthermore, when the condition monitoring device 40 receives sensing data exceeding the threshold value th from the sensor 50, the condition monitoring device 40 extracts sensing data for a predetermined period P2 before and after the received data from the sensing data indicated by waveform 201, and transmits the extracted sensing data to the machine tool 10. In the example of FIG. 2 , the time t2 at which the threshold value th is exceeded is used as a reference, and sensing data of waveform 204, which is sensing data before and after the time t2, is extracted. The predetermined periods P1 and P2 according to this embodiment are each set in advance, and the condition monitoring device 40 retains this information so that it can be referenced. Note that the predetermined periods P1 and P2 may be the same value (time width) or different values ​​(time width). Furthermore, FIG. 2 illustrates an example in which the predetermined period P2 is set to the same period before and after the time t2 at which the threshold value th is exceeded, but different periods may be set before and after the reference time. Furthermore, in the present embodiment, an example has been shown in which sensing data is transmitted to the control device 30 based on a periodic control signal (ON signal) originating from the control device 30, but the present invention is not limited to this. The state monitoring device 40 may be configured to manage the periodicity and transmit the sensing data to the control device 30 at a predetermined period.

[0027] Fig. 3 is a diagram for explaining how the sensing data received from condition monitoring device 40 is used by control device 30 of machine tool 10. In Fig. 3, the horizontal axis represents time t, and the vertical axis represents signal values. Note that the time scale shown on the horizontal axis in Fig. 3 is larger than the time scale shown on the horizontal axis in Fig. 2. For example, if the scale of the horizontal axis in Fig. 2 is seconds, the scale of the horizontal axis in Fig. 3 may be date and time.

[0028] 3 shows an example of transitions in signal values ​​based on three pieces of sensing data acquired from three sensors 50. Lines 301, 302, and 303 shown in Fig. 3 are each composed of signal values ​​derived based on sensing data received from the condition monitoring device 40, i.e., sensing data acquired during the predetermined period P1 and the predetermined period P2 in Fig. 2. For convenience, data such as that shown in Fig. 3 is also referred to as "trend data."

[0029] Furthermore, in this embodiment, thresholds Th1, Th2, and Th3 are set corresponding to lines 301, 302, and 303, respectively. Threshold Th1 corresponds to line 301. Threshold Th1 is derived based on the signal values ​​represented by line 301 that are included in the period from the start time (e.g., time t = 0) to a predetermined time. Threshold Th1 may be derived, for example, by using the average value Ave and standard deviation σ for that period, as Th1 = Ave + 3σ. Threshold Th2 corresponds to line 302. Threshold Th2 is also derived based on the signal values ​​represented by line 302 that are included in the period from the start time (e.g., time t = 0) to a predetermined time. Threshold Th3 corresponds to line 303. Threshold Th3 is also derived based on the signal values ​​represented by line 303 that are included in the period from the start time (e.g., time t = 0) to a predetermined time.

[0030] Furthermore, in this embodiment, if any of the lines 301, 302, and 303 exceeds the corresponding threshold, it is determined that one of the replaceable parts 21 in the mechanical unit 20 needs to be replaced, and information regarding ordering the relevant replaceable part 21 is presented. For example, the sensing data used to derive the signal value of the line 301 and the replaceable part 21 corresponding to the sensor 50 that measured the sensing data are defined in advance, and this information is stored in a database or the like. Then, based on this definition, the type of replaceable part 21 is identified in accordance with the signal value that exceeds the threshold. The replaceable part 21 identified here may be of one type or multiple types.

[0031] The method for calculating the threshold value corresponding to each signal value is not limited to the above formula, and calculation may be based on other statistical methods. Furthermore, the threshold value corresponding to each signal value may be manually set or adjusted by the user. For example, the threshold value may be determined as an initial value using the above formula, and the user may change the threshold value at any time.

[0032] [UI Screen Example] Figure 4 is a diagram showing an example of the configuration of a UI screen 400 displayed on the UI unit 33 of the machine tool 10 according to this embodiment. Here, as described using Figure 3, an example of the configuration of a UI screen that is displayed when it is determined that any of the replaceable parts 21 needs to be replaced is shown. The UI unit 33 capable of displaying the UI screen 400 will be described as being configured as a touch panel display.

[0033] The UI screen 400 includes a trend data display area 410 and an operation area 420. In the trend data display area 410, trend data including signal values ​​based on sensing data measured by the sensors 50 and corresponding threshold values, as shown in FIG. 3, is displayed in a graph format. In the example of FIG. 4, three signal values ​​based on sensing data obtained by three sensors 50 are shown. A line 411 represents a signal value related to the "spindle unit (spindle)" of the mechanism section 20, and an explanatory icon 412 is associated with this signal value. A line 413 represents a signal value related to the "feed mechanism: X-axis" of the mechanism section 20, and an explanatory icon 414 is associated with this signal value. A line 415 represents a signal value related to the "feed mechanism: Y-axis" of the mechanism section 20, and an explanatory icon 416 is associated with this signal value.

[0034] In the example of Figure 4, the signal value (line 411) corresponding to "spindle unit" is shown to exceed the corresponding threshold value 417. Note that the signal values ​​(lines 413, 415) corresponding to "feed mechanism: X-axis" and "feed mechanism: Y-axis" are not considered to exceed their corresponding threshold values, and the corresponding threshold values ​​are omitted here. Note that these threshold values ​​may also be displayed.

[0035] 4, if it is determined that the signal value (line 411) corresponding to the "spindle unit" exceeds the corresponding threshold value 417, an item for ordering the replaceable part 21 related to that spindle unit is displayed in the operation area 420. In other words, if there is no signal value exceeding the threshold value, the operation screen of the operation area 420 may be hidden, and only the trend data in the trend data display area 410 may be displayed.

[0036] In the operation area 420, an item 421 indicates information about parts recommended for replacement. In this example, "spindle unit" is displayed corresponding to the line 411. Furthermore, replaceable parts 21 included in the "spindle unit," i.e., parts that can be ordered, are displayed in a list format in a list 422.

[0037] In list 422, item 422a indicates replaceable parts 21 that can be ordered. In this example, "bearing 1" to "bearing 5" are replaceable parts corresponding to the spindle unit. These correspondences are defined in advance and registered in a database (not shown) or the like. Item 422b indicates current delivery date information for each replaceable part shown in item 422a. The delivery date information is acquired by machine tool 10 making an inquiry to inventory management system 60. Item 422c indicates the number of each replaceable part shown in item 422a required for replacement. The quantity information is defined in advance according to the part identified in mechanism section 20 (e.g., "spindle unit") and registered in a database (not shown) or the like. Item 422d is an area for inputting the number to be ordered for each replaceable part shown in item 422a. Item 422d can be input by the user at will.

[0038] Order button 423 is a button that the user uses to issue an instruction when ordering replaceable part 21. When the user inputs the desired number in item 422d and selects order button 423, machine tool 10 issues an order instruction to inventory management system 60 for the relevant replaceable part 21.

[0039] 4, both the trend data display area 410 and the operation area 420 can be displayed, but only the operation area 420 may be displayed. In this case, an operation screen for placing an order may be displayed when the signal value exceeds the corresponding threshold. Furthermore, the icons 412, 414, and 416 in the trend data display area 410 may be configured to be switchable between display and non-display.

[0040] 4 shows only one example (here, line 411) of a signal value exceeding the threshold. When multiple signal values ​​exceed the threshold, operation areas 420 may be displayed corresponding to the respective body parts. In this case, lists may be displayed so that they can be switched for each body part, or the lists may be displayed together as a single list.

[0041] 5A and 5B are diagrams for explaining archiving of trend data in machine tool 10 according to this embodiment. In Figures 5A and 5B, the horizontal axis represents time t, and the vertical axis represents signal value. The trend data here corresponds to trend data derived by machine tool 10 when it acquires sensing data from condition monitoring device 40, as in Figure 3.

[0042] In Fig. 5A, machine tool 10 starts operating using replaceable part 21 at time ta, and sensing data is acquired in response to this, and trend data is derived. Then, at time tb, the signal value in the trend data exceeds the associated threshold value Th0. In this case, at time tb, the operation screen for operation area 420 is displayed, as shown in UI screen 400 in Fig. 4. Furthermore, if a new replaceable part 21 is replaced at a later time tc, the signal value will decrease as a result. It is assumed that machine tool 10 will be stopped for a predetermined period of time during part replacement, but this period will not be described here.

[0043] In this case, the machine tool 10 archives and stores the trend data obtained during the period Po from time ta to time tc, i.e., before the part replacement, and resets the trend data. In other words, only the trend data obtained after the part replacement is held as the monitoring target. Archiving may involve, for example, compressing the target data or moving it to a specified storage area. In archiving, the relevant trend data may be associated with information about the replaced part and information about the time of replacement, and recorded as a replacement history.

[0044] 5B shows trend data for a period Pn after time tc, i.e., after part replacement. The machine tool 10 derives and sets a threshold value Thn for the trend data after part replacement using trend data included in a predetermined period Pt (times tc to td) based on the time at which the part replacement was performed (here, time tc). As described above with reference to FIG. 3, the threshold value Thn may be derived using the average value and standard deviation (Thn = Ave + 3σ) for the period Pt. In other words, each time a replaceable part 21 is replaced, trend data for the past part is archived, and a threshold value is set for the new part.

[0045] Note that the control device 30 of the machine tool 10 may control the mechanical unit 20 to execute a predetermined operation pattern during the period Pt immediately after the part is replaced. By executing a predetermined operation pattern, a comparable threshold value can be derived based on sensing data in an operating state under certain conditions. The predetermined operation pattern may be predefined depending on the replaced part and the configuration of the mechanical unit 20, and for example, control parameters such as the rotation speed and rotation angle, an implementation period, etc. may be specified as the diagnostic operation.

[0046] Note that archiving may be performed when a part is replaced, regardless of whether the signal value of the trend data exceeds the threshold value.

[0047] [Processing Sequence] Figures 6 and 7 are sequence diagrams showing the processing flow of the system according to this embodiment. The processing in each device may be realized by a processing unit provided in each device reading and executing a program stored in a memory unit, or may be executed by a dedicated circuit serving as a processing unit. For simplicity of explanation, each device is shown individually, as in Figure 1, but if multiple devices are provided, each device processes simultaneously in parallel. This processing sequence may be executed continuously while the machine tool 10 is operating.

[0048] In step S601, the sensor 50 measures the surroundings of the mechanical unit 20 to be monitored in the machine tool 10, and acquires sensing data.

[0049] In step S602, the sensor 50 transmits the sensing data acquired in step S601 to the condition monitoring device 40. Then, the processing of the sensor 50 returns to the process of step S601 and the processing is repeated. The sensing data may be transmitted each time a signal is detected, or may be transmitted in bulk at regular intervals.

[0050] In step S611, the state monitor 40 receives sensing data from the sensor 50.

[0051] In step S612, the status monitoring device 40 records the sensing data received in step S611 in a storage unit (not shown) such as a cache. Note that the status monitoring device 40 may periodically erase past sensing data depending on the capacity of the storage unit.

[0052] In step S613, condition monitoring device 40 determines whether or not a control signal has been received from control device 30 of machine tool 10. The control signal here corresponds to the ON signal of control signal 202 shown in FIG. 2. If a control signal has been received (YES in step S613), the processing of condition monitoring device 40 proceeds to step S614. On the other hand, if a control signal has not been received (NO in step S613), the processing of condition monitoring device 40 proceeds to step S615.

[0053] In step S614, condition monitoring device 40 extracts sensing data for a certain period from the timing of receiving the control signal and transmits the data to machine tool 10. More specifically, as shown in FIG. 2, sensing data included in predetermined period P1 is transmitted to machine tool 10. Thereafter, the processing of condition monitoring device 40 proceeds to step S615.

[0054] In step S615, the status monitoring device 40 determines whether the signal value of the sensing data received from the sensor 50 exceeds a threshold value. That is, the status monitoring device 40 determines whether an abnormal value has been detected in the sensing data. The threshold value here corresponds to the threshold value th shown in FIG. 2 and is assumed to be predefined. If an abnormal value has been detected (YES in step S615), the processing of the status monitoring device 40 proceeds to step S616. On the other hand, if an abnormal value has not been detected (NO in step S615), the processing of the status monitoring device 40 returns to the process of step S611 and repeats the processing. Note that the "abnormal value" here does not necessarily require the device itself to be stopped or any control parameters or operating conditions of the device to be changed, but may be a value used as one element for status monitoring.

[0055] In step S616, condition monitoring device 40 extracts signals for a predetermined period before and after the timing at which the abnormal value was detected, and transmits them to machine tool 10. More specifically, as shown in Fig. 2, sensing data included in predetermined period P2 is transmitted to machine tool 10. Thereafter, the processing of condition monitoring device 40 returns to the process of step S611, and the processing is repeated.

[0056] In step S621, the control device 30 sets a threshold value for the signal value. The threshold value may be derived based on sensing data that has already been received, or a value that is predefined as an initial value may be used.

[0057] In step S622, the control device 30 determines whether a predetermined period has been reached. The start timing and interval of the predetermined period are assumed to be specified in advance. If the predetermined period has been reached (YES in step S622), the process of the control device 30 proceeds to step S623. On the other hand, if the predetermined period has not been reached (NO in step S622), the process of the control device 30 proceeds to step S624.

[0058] In step S623, control device 30 transmits a control signal to state monitoring device 40. This control signal corresponds to the ON signal of control signal 202 shown in Fig. 2. Thereafter, the process of control device 30 proceeds to step S624.

[0059] In step S624, the control device 30 receives the sensing data transmitted from the condition monitoring device 40. The sensing data here includes sensing data transmitted in response to the control signal transmitted in step S623 and sensing data transmitted when an abnormal value is detected on the condition monitoring device 40 side.

[0060] In step S625, the control device 30 records the sensing data received in step S624 in the storage unit 32. At this time, the control device 30 displays trend data based on the received sensing data in the trend data display area 410 of the UI screen 400, as shown in FIG. 4, to present the transition of the state to the user.

[0061] In step S626, control device 30 determines whether the signal value as trend data has exceeded a threshold value. The threshold value here is a threshold value set in association with each signal value and corresponds to threshold values ​​Th1, Th2, Th3, etc. in FIG. 3. If the signal value has exceeded the threshold value (YES in step S626), the process of control device 30 proceeds to step S627. If the signal value has not exceeded the threshold value (NO in step S626), the process of control device 30 proceeds to step S628.

[0062] In step S627, the control device 30 executes a UI generation process. In this process, an operation screen to be displayed in the operation area 420 of the UI screen 400 as shown in Fig. 4 is generated. The process of this process will be described in detail with reference to Fig. 7. Thereafter, the process of the control device 30 proceeds to step S628.

[0063] In step S628, control device 30 determines whether or not a replacement of replaceable part 21 has occurred. If a part replacement has occurred (YES in step S628), the process of control device 30 proceeds to step S629. On the other hand, if a part replacement has not occurred (NO in step S628), the process of control device 30 returns to the process of step S622 and repeats the process.

[0064] In step S629, the control device 30 archives the recorded trend data up to the time when the part replacement occurred. More specifically, the trend data included in the period Po shown in FIG. 5A is archived. Then, the process of the control device 30 proceeds to step S630.

[0065] In step S630, the control device 30 calculates a new threshold value using signals included in a predetermined period of time based on the timing of the part replacement, from among the recorded trend data. More specifically, the new threshold value is calculated using signals included in the period Pt as shown in FIG. 5B. Note that if the period Pt has not yet elapsed since the part replacement, this step may be performed after the period Pt has elapsed. As described above, during the period Pt, the control device 30 controls the mechanical unit 20 to execute a predetermined operation pattern.

[0066] In step S631, the control device 30 sets the new threshold calculated in step S631, and then the process of the control device 30 returns to the process of step S622 to repeat the process.

[0067] (UI Generation Process) FIG. 7 is a sequence diagram showing the process executed in step S627 of FIG.

[0068] In step S701, the control device 30 identifies a replaceable part corresponding to a signal value exceeding a threshold value. As described above, the sensing data is measured from around the mechanical unit 20, and this sensing data is assumed to be associated in advance with the replaceable parts 21 in the mechanical unit 20. In the example of FIG. 4, the "spindle unit" corresponding to the line 411 based on the sensing data is associated in advance in a database or the like with the replaceable parts 21, "bearing 1" to "bearing 5," and these replaceable parts 21 are identified.

[0069] In step S702, the control device 30 derives the required number of the replaceable parts 21 identified in step S701. The required number may be defined in advance in a database or the like, and may be derived based on this.

[0070] In step S703, the control device 30 inquires about delivery date information from the inventory management system 60 based on the type of replaceable part 21 identified in step S701 and the required quantity calculated in step S702. Then, the process of the control device 30 proceeds to step S704.

[0071] In step S704, the control device 30 acquires delivery date information in response to the inquiry in step S703 from the inventory management system 60. Then, the control device 30 generates an operation screen to be displayed in the operation area 420 in Fig. 4 based on the delivery date information, the replaceable parts 21 identified in step S701, and the required quantity derived in step S702. Then, the processing of the control device 30 proceeds to step S705.

[0072] In step S705, the control device 30 causes the UI screen 400 including the operation screen generated in step S704 to be displayed on the UI unit 33. This enables the control device 30 to receive information on replaceable parts 21 recommended for replacement and an ordering instruction from the user.

[0073] In step S706, the control device 30 determines whether or not an order instruction has been received via the UI screen 400. If an order instruction has been received (YES in step S706), the process of the control device 30 proceeds to step S707. On the other hand, if an order instruction has not been received (NO in step S706), the process of the control device 30 proceeds to step S708.

[0074] In step S707, the control device 30 performs an order process for the inventory management system 60 based on the order instruction received via the UI screen 400. Then, the control device 30 closes the operation screen of the operation area 420 displayed on the UI screen 400, ends this processing sequence, and the processing of the control device 30 proceeds to step S628 in FIG.

[0075] In step S708, the control device 30 periodically updates the UI screen 400 based on newly received sensing data. For example, the control device 30 periodically updates the content of the trend data display area 410 of the UI screen 400. At this time, the control device 30 may continue the process of step S708 in FIG. 7 while simultaneously executing the processes from step S628 onward in FIG. 6. Therefore, the display and update process of the UI screen in step S708 may be executed until an order instruction is received via the operation area 420 of the UI screen 400 or an explicit instruction not to perform order processing is received.

[0076] In step S711, the inventory management system 60 receives the inquiry from the control device 30 and, based on the content of the inquiry, derives delivery date information for the desired replaceable part 21. Delivery date information for each replaceable part 21 may be collected by the inventory management system 60 periodically by making an inquiry to an external system 70 such as a manufacturer that is the provider of the replaceable part 21. Then, the inventory management system 60 derives delivery date information for the inquiry based on the information collected from the external system 70 and the inquiry received from the control device 30.

[0077] In step S712, the inventory management system 60 transmits the delivery date information derived in step S711 to the control device 30 as a response to the inquiry.

[0078] In step S713, when the inventory management system 60 receives the order information from the control device 30, the inventory management system 60 performs an order process for the desired replaceable part 21 to the external system 70 based on the order information.

[0079] In step S721, when external system 70 receives an order for a desired replaceable part 21 from inventory management system 60, external system 70 executes processing to deliver the replaceable part 21 to a predetermined delivery destination (for example, the base where machine tool 10 is installed). Information about the delivery destination here may be registered in advance in inventory management system 60, etc.

[0080] As described above, this embodiment makes it possible to improve the convenience of part replacement and data management when using a machine tool. More specifically, it makes it possible to recommend the replacement of replaceable parts based on sensing data. Furthermore, in particular, an operation screen such as that shown in FIG. 4 allows the user to easily grasp the type and number of parts to be replaced. Furthermore, it is possible to easily check the delivery date of the parts to be replaced, improving the convenience of the ordering process. Furthermore, by presenting state transitions based on sensing data, the user can easily recognize which parts are more worn. Furthermore, when a part is replaced, it is possible to easily manage data measured up to that point. Furthermore, it is possible to automatically set thresholds for determining the state of the part depending on before and after replacement.

[0081] [Modification] A modification of the system according to the present embodiment will be described. For example, in anticipation of wear and tear of replaceable parts 21 due to operation of machine tool 10, the base where machine tool 10 is installed may hold and manage some spare replaceable parts 21 in advance. In this way, if there is stock of replaceable parts 21 at the base, it is sufficient to use those parts, and there is no need to order them. Therefore, in a modification of this embodiment, a base inventory management system 80 is provided that manages the in-base inventory already held at the base. Then, machine tool 10 further cooperates with base inventory management system 80 to improve convenience regarding ordering.

[0082] Fig. 8 shows an example of a system configuration according to a modified example. The difference from Fig. 1 is that a base inventory management system 80 is newly provided. The base inventory management system 80 is configured, for example, by an information processing device, and inventory information of replaceable parts 21 held at the base is registered in an inventory DB 81. The information registered in the inventory DB 81 may be updated, for example, by a manager of the machine tool 10 at the base. The base inventory management system 80 provides the information held in the inventory DB 81 in response to an inquiry from the control device 30 of the machine tool 10.

[0083] Fig. 9 shows an example of the configuration of a UI screen 900 according to this modified example. As explained above in Figs. 6 and 7, UI screen 900 is generated by the UI generation process and displayed on UI section 33 of machine tool 10. Here, trend data display area 410 as shown in Fig. 4 is omitted, and the explanation will be given by taking a "spindle unit" as an example of a part recommended for replacement.

[0084] In the example of FIG. 9 , when it is determined that the signal value corresponding to the "spindle unit" exceeds the corresponding threshold value, an item for ordering a replaceable part 21 related to the spindle unit is displayed on the UI screen 900. Item 901 indicates information about a part recommended for replacement. In this example, the "spindle unit" is displayed. Furthermore, the replaceable parts 21 included in the "spindle unit," i.e., the parts that can be ordered, are displayed in a list format in list 902.

[0085] In the list 902, item 902a indicates replaceable parts 21 that can be ordered. In this example, "bearing 1" to "bearing 5" are replaceable parts corresponding to the spindle unit. This correspondence is defined in advance and registered in a database (not shown) or the like. Item 902b indicates current delivery date information for each replaceable part shown in item 902a. The delivery date information is obtained by the machine tool 10 making an inquiry to the inventory management system 60. Item 902c indicates the number of each replaceable part shown in item 902a required for replacement. The quantity information is defined in advance according to the part identified in the mechanical section 20 (e.g., "spindle unit") and registered in a database (not shown) or the like. Item 902d indicates the number of replaceable parts 21 shown in item 902a that are held in stock at the base. The value of item 902d may be obtained by making an inquiry to the base inventory management system 80. Item 902e is an area for inputting the quantity to be ordered for each replaceable part shown in item 902a. The user can input any quantity into item 902e.

[0086] The order button 903 is a button used to issue an order for replaceable parts 21. When the user inputs the desired number in item 903e and selects the order button 903, the machine tool 10 issues an order instruction for the relevant replaceable parts 21 to the inventory management system 60.

[0087] The input for item 902e may be an arbitrary value input by the user based on the required quantity shown in item 902c and the on-site inventory quantity shown in item 902d. Alternatively, the order quantity may be controlled so that it is limited by the difference between the required quantity shown in item 902c and the on-site inventory quantity shown in item 902d, or by the required quantity shown in item 902c. Alternatively, a configuration may be adopted in which a warning screen is displayed when an order quantity equal to or greater than a predetermined value is input.

[0088] Furthermore, the delivery date information shown in the item 902b may be updated according to the input value of the order quantity in the item 902e. In this case, the control device 30 may make an inquiry to the inventory management system 60 every time the input value of the order quantity is changed.

[0089] As described above, this modified example makes it possible to present an operation screen for ordering that takes into account inventory at the base, and in addition to the effects of the first embodiment, it is possible to further improve the convenience for users regarding ordering.

[0090] Other Embodiments Some of the processing of the present invention may be implemented using a trained model based on machine learning. For example, when deriving a threshold value corresponding to sensing data such as that shown in FIG. 3, a trained model may be used that has undergone a learning process using input data as sensing data and output data as threshold values. Because the learning process generally involves a high load, the learning process is executed in advance in another system to generate a trained model. It is then desirable to configure the control device 30 of the machine tool 10 so that the trained model can be used when deriving a threshold value. It is also desirable to generate a trained model for each combination of data types measured by the mechanical unit 20 and the sensor 50.

[0091] Furthermore, the configuration of the training data for generating a trained model and the configuration of the data input to the trained model for deriving a threshold value may be the sensing data itself, or may be data that has been subjected to a certain amount of preprocessing. The preprocessing of the sensing data may vary depending on the type of learning algorithm, the configuration of the machine tool or sensor, etc.

[0092] Furthermore, in the present invention, a program or application for realizing the functions of one or more of the above-described embodiments can be supplied to a system or device using a network or a storage medium, etc., and one or more processors in the computer of the system or device can read and execute the program, thereby realizing the present invention.

[0093] Alternatively, the functions may be realized by a circuit that realizes one or more functions (for example, an ASIC (Application Specific Integrated Circuit) or an FPGA (Field Programmable Gate Array)).

[0094] Furthermore, in this specification, the terms "first" and "second" are used merely to distinguish from other elements and are not intended to be interpreted as being limited to specific elements. Therefore, these terms may be interpreted appropriately depending on the configuration to which the present invention is applied.

[0095] As such, the present invention is not limited to the above-described embodiments, and the present invention also contemplates the mutual combination of the various components of the embodiments, as well as modifications and applications by those skilled in the art based on the description in the specification and well-known techniques, and these modifications and applications are included in the scope of protection sought.

[0096] As described above, the present specification discloses the following: (1) A system including a machine tool (e.g., 10) including a replaceable part (e.g., 21), a sensor (e.g., 50) that measures the machine tool, and a condition monitoring device (e.g., 40) that manages sensing data measured by the sensor, wherein the machine tool includes: acquisition means (e.g., 31, 34) that acquires sensing data (e.g., 203, 204) at a predetermined timing from sensing data (e.g., 201) held in the condition monitoring device; derivation means (e.g., 31) that uses at least a portion of the sensing data acquired by the acquisition means (e.g., sensing data of Pt) to derive a threshold value (e.g., Thn) corresponding to the sensing data; and display control means (e.g., 31) that displays a display screen (e.g., 400, 410) that shows transitions in signal values ​​of the sensing data acquired by the acquisition means. The system includes: an identification unit (e.g., 31) that, when a signal value of the sensing data acquired by the acquisition unit exceeds the threshold, identifies a replaceable part of the machine tool predefined as a measurement target of the sensor acquiring the sensing data as a replacement target (e.g., 422a); and the display control unit, when the identification unit identifies a replaceable part, displays information about the replaceable part (e.g., 400, 420) on the display screen. This configuration improves the convenience of part replacement and data management when using the machine tool. More specifically, it is possible to recommend replacement of replaceable parts based on the sensing data. It also allows the user to easily grasp the type and number of parts to be replaced. It also allows the user to easily recognize which parts are worn out by presenting state transitions based on the sensing data. It also allows the user to automatically set thresholds for determining the state of parts before and after replacement.

[0097] (2) The system according to (1), wherein the system is communicably connected to an inventory management system (e.g., 60) that manages delivery date information for replaceable parts of the machine tool, the machine tool further has means (e.g., 31, 34) for inquiring of the inventory management system about delivery dates for replaceable parts identified by the identification means, and the display control means displays delivery date information (e.g., 422b) acquired from the inventory management system as information on the replaceable parts. With this configuration, a user can easily grasp the delivery date of a replaceable part identified as a target for replacement.

[0098] (3) The system according to (2), wherein the display control means is configured to be able to receive, on the display screen, the order quantity and order instruction for the replaceable part identified by the identification means (e.g., 422d, 423), and the machine tool further has ordering means (e.g., 31, 34) that issues an order instruction to the inventory management system based on the order quantity and order instruction for the replaceable part received on the display screen. With this configuration, a user can easily perform the work of ordering the replaceable part while understanding the replaceable part identified as the part to be replaced.

[0099] (4) The system according to any one of (1) to (3), further comprising: a management system (e.g., 80) that manages the inventory of replaceable parts for the machine tool at a base where the machine tool is installed, the machine tool further comprising: means (e.g., 31, 34) for inquiring of the management system about the inventory of the replaceable part at the base identified by the identification means, and the display control means displays inventory information at the base acquired from the management system (e.g., 902d) as information about the replaceable part. With this configuration, a user can easily grasp the inventory of replaceable parts at the base where the machine tool is installed and can issue an ordering instruction based on this information.

[0100] (5) The system according to any one of (1) to (4), wherein the derivation means derives the threshold value corresponding to the sensing data using a statistical calculation method (e.g., average and standard deviation) for the signal value of the sensing data. With this configuration, it is possible to automatically calculate the threshold value corresponding to the sensing data using a simple calculation method.

[0101] (6) The system according to any one of (1) to (4), wherein the derivation means derives the threshold value using a trained model generated by performing a learning process using sensing data as input data and a threshold value for the sensing data as output data. With this configuration, it is possible to automatically derive a threshold value corresponding to the sensing data using a trained model generated in advance by machine learning.

[0102] (7) The system according to any one of (1) to (6), wherein, when a replaceable part of the machine tool is replaced, the derivation means derives the threshold value using sensing data measured within a predetermined period from the replacement, and the machine tool has control means (e.g., 31) that operates a mechanical part (e.g., 20) including the replaceable part in a predefined operation pattern within the predetermined period (e.g., Pt) from the replacement. This configuration makes it possible to derive a more appropriate threshold value based on operation under certain conditions.

[0103] (8) The system according to any one of (1) to (7), wherein the acquiring means acquires, as the sensing data at the predetermined timing, sensing data at periodic intervals (e.g., 203) and sensing data for a predetermined period before and after a reference point at which a signal exceeding a predetermined value is detected (e.g., 204). With this configuration, it is possible to suppress the amount of sensing data and to perform processing on sensing data that takes into account the state of the machine tool.

[0104] (9) The system according to any one of (1) to (8), wherein the machine tool further includes a processing unit (e.g., 31) that, when a replaceable part is replaced, performs archiving by recording sensing data (e.g., sensing data of Po) acquired up to the time of the replacement in association with information about the replaceable part. This configuration allows for easy management of data measured up to that point when a part is replaced. Furthermore, it is possible to derive a threshold value corresponding to the replaced replaceable part without being affected by past sensing data.

[0105] (10) A control method for a machine tool (e.g., 10) including a replaceable part (e.g., 21), comprising: an acquisition step (e.g., step 624) of acquiring sensing data (e.g., 203, 204) at a predetermined timing from sensing data (e.g., 201) held in a status monitoring device (e.g., 40) that manages sensing data obtained by measurements made on the machine tool by a sensor (e.g., 50); a derivation step (e.g., S630, S631) of deriving a threshold value corresponding to the sensing data using at least a portion of the sensing data acquired in the acquisition step (e.g., sensing data of Pt); and a display control step (e.g., S625, S627) of displaying a display screen (e.g., 400, 410) showing transitions in signal values ​​of the sensing data acquired in the acquisition step. A machine tool control method includes: an identification step (e.g., S701 to S704) of identifying a replaceable part of the machine tool predefined as a measurement target of the sensor acquiring the sensing data as a replacement target (e.g., 422a) when the signal value of the sensing data acquired in the acquisition step exceeds the threshold; and, in the display control step, when a replaceable part is identified in the identification step, displaying information about the replaceable part on the display screen (e.g., 400, 420). This configuration improves the convenience of part replacement and data management when using the machine tool. More specifically, it is possible to recommend replacement of replaceable parts based on the sensing data. It also allows the user to easily grasp the type and number of parts to be replaced. It also allows the user to easily recognize which parts are worn out by presenting state transitions based on the sensing data. It also allows the user to automatically set thresholds for determining the state of the part before and after replacement.

[0106] Although various embodiments have been described above with reference to the drawings, it goes without saying that the present invention is not limited to such examples. It is clear that a person skilled in the art can conceive of various modifications or alterations within the scope of the claims, and it is understood that these also naturally fall within the technical scope of the present invention. Furthermore, the components of the above-described embodiments may be combined in any manner without departing from the spirit of the invention.

[0107] Although various embodiments have been described above, it goes without saying that the present invention is not limited to such examples. It is clear that a person skilled in the art can conceive of various modifications or alterations within the scope of the claims, and it is understood that these also naturally fall within the technical scope of the present invention. Furthermore, the components of the above embodiments may be combined in any manner as long as they do not deviate from the spirit of the invention.

[0108] This application is based on a Japanese patent application (Patent Application No. 2023-149279) filed on September 14, 2023, the contents of which are incorporated herein by reference.

[0109] DESCRIPTION OF SYMBOLS 10: Machine tool 20: Mechanical section 21: Replaceable part 30: Control device 31: Processing section 32: Storage section 33: UI section 34: Communication section 40: Status monitoring device 50: Sensor 60: Inventory management system 70: External system 80: Base inventory management system

Claims

1. A system comprising a machine tool including a replaceable part, a sensor that performs measurements on the machine tool, and a condition monitoring device that manages sensing data obtained by measurement by the sensor, wherein the machine tool has: an acquisition means that acquires sensing data at a predetermined timing from the sensing data held in the condition monitoring device; a derivation means that uses at least a portion of the sensing data acquired by the acquisition means to derive a threshold value corresponding to the sensing data; a display control means that displays a display screen showing changes in the signal value of the sensing data acquired by the acquisition means; and an identification means that, when the signal value of the sensing data acquired by the acquisition means exceeds the threshold value, identifies a replaceable part of the machine tool that has been predefined as a measurement target by the sensor that acquired the sensing data as a part to be replaced, and when a replaceable part is identified by the identification means, the display control means displays information of the replaceable part on the display screen.

2. The system described in claim 1, wherein the system is communicatively connected to an inventory management system which manages delivery date information of replaceable parts of the machine tool, the machine tool further has a means for inquiring of the inventory management system about the delivery date of the replaceable part identified by the identification means, and the display control means displays the delivery date information obtained from the inventory management system as information about the replaceable part.

3. The system described in claim 2, wherein the display control means is configured to be able to accept on the display screen the order quantity and ordering instructions for the replaceable parts identified by the identification means, and the machine tool further has an ordering means for issuing an ordering instruction to the inventory management system based on the order quantity and ordering instructions for the replaceable parts accepted on the display screen.

4. The system according to claim 1, further comprising: a management system that manages the inventory of replaceable parts for the machine tool at the base where the machine tool is installed, the machine tool further comprising: a means for inquiring of the management system about the inventory at the base of the replaceable parts identified by the identification means; and the display control means displays information about the inventory at the base obtained from the management system as information about the replaceable parts.

5. The system according to claim 1, wherein the deriving means derives the threshold value corresponding to the sensing data by using a statistical calculation method for the signal value of the sensing data.

6. The system according to claim 1, wherein the derivation means derives the threshold value using a trained model generated by performing a learning process using sensing data as input data and a threshold value for the sensing data as output data.

7. The system according to claim 1, wherein the derivation means derives a threshold value using sensing data measured within a predetermined period from the replacement of a replaceable part of the machine tool, and the machine tool has control means for operating a mechanical part including the replaceable part in a predefined operating pattern within the predetermined period from the replacement.

8. The system according to claim 1, wherein the acquisition means acquires sensing data at periodic intervals and sensing data for a specified period before and after a point in time when a signal exceeding a specified value is detected as sensing data at the specified timing.

9. The system according to claim 1, wherein the machine tool further comprises a processing means for performing archiving, when a replaceable part is replaced, in which the sensing data acquired up until the replacement is associated with information on the replaceable part and recorded.

10. A control method for a machine tool including a replaceable part, comprising: an acquisition step of acquiring sensing data at a predetermined timing from sensing data held in a condition monitoring device that manages sensing data obtained by measurements of the machine tool by sensors; a derivation step of deriving a threshold value corresponding to the sensing data using at least a portion of the sensing data acquired in the acquisition step; a display control step of displaying a display screen showing changes in the signal value of the sensing data acquired in the acquisition step; and an identification step of identifying, when the signal value of the sensing data acquired in the acquisition step exceeds the threshold value, a replaceable part of the machine tool that has been predefined as a measurement target by the sensor that acquired the sensing data, as a part to be replaced, wherein, when a replaceable part is identified in the identification step in the display control step, information of the replaceable part is displayed on the display screen.

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