Machine inspection method and system for carrying out a machine inspection method

Abstract

The invention relates to a machine inspection method for carrying out checks on a machining tool (1), in particular on a laser and / or punching machining tool, for machining workpieces (9), wherein: the machining tool (1) has a plurality of machine units (2); the machining tool (1) has a movable machining head (3); a camera (4) is fastened to the machining head (3); a first image (5) of a first machine unit (2) of the plurality of machine units (2) is generated by means of the camera (4); on the basis of the first image (5) a first state of the first machine unit (2) is determined; the first state is compared with at least one first prerequisite for a first machining program (6), in particular a laser cutting and / or punching machining program; and the first machining program (6) is executed when it is recognised that the first state meets the first prerequisite.

Description

[0001] Machine inspection procedure and system for carrying out a machine inspection procedure

[0002] The invention relates to a machine inspection method for performing inspections on a processing machine for machining workpieces, in particular a laser and / or punching machine, using a camera attached to a machining head of the processing machine. Furthermore, the invention relates to a system for performing a machine inspection method.

[0003] From US 2020 / 0331095 A1 the use of a camera, which is attached to a processing head, for imaging in a processing machine is known.

[0004] The object of the invention is to further develop the state of the art.

[0005] The object is achieved by a machine inspection method according to claim 1 and a system according to claim 13. Advantageous embodiments are specified in the subclaims.

[0006] A machine inspection method is disclosed for carrying out checks on a processing machine, in particular on a laser and / or punching processing machine, for processing workpieces, wherein the processing machine has a plurality of machine units, wherein the processing machine has a movable processing head, wherein a camera is attached to the processing head, wherein a first image of a first machine unit of the plurality of machine units is created with the camera, wherein a first state of the first machine unit is determined based on the first image, wherein the first state is compared with at least one first prerequisite for a first machine processing program, in particular a laser cutting and / or a punching processing program, wherein the first machine processing program is executed if fulfillment of the first prerequisite is detected by the first state.The first requirement may include requirements for several of the majority of machine units.

[0007] When machining workpieces with processing machines, such as laser cutting and / or punching machines, certain requirements must be met for a machining program to achieve a desired result. Such requirements include, for example, proper tool setup required for machining. Such requirements also include, for example, a machining space between a tool and a workpiece to be machined that must be free of any foreign matter, such as reject elements on the raw material to be machined, which typically arise in a separating machining process.Furthermore, such prerequisites may include correct machine settings to achieve a quality requirement to be met, for example, sufficient cleanliness and / or flatness of the support of the raw material to be machined. Furthermore, such prerequisites may also include correct parameter selection to achieve a quality requirement to be met, such as sufficient cutting quality for a cut workpiece contour.

[0008] In order to verify the degree to which such requirements are met, the states of machine units relevant to the respective requirements must be recorded. This is typically achieved using various sensors, often optical sensors, especially camera-based sensors. Such sensors must meet dynamic and demanding production conditions and record various machine states. This is typically problematic in the context of processing machines because, on the one hand, such sensors are expensive and, on the other hand, space constraints often prevent them from being placed on each different machine unit on which a state is to be measured. This is also one reason why inspections for such state recording often have to be carried out manually, which is time-consuming and error-prone.

[0009] The camera attached to the machining head of the processing machine can record the various states at different points on the processing machine. This means that only one camera is needed for states on multiple machine units. By comparing the recorded state with the prerequisites for the respective machining program to be executed, deviations from these prerequisites can be identified. The comparison can therefore also be automated and does not have to be carried out manually. If the state deviates from the prerequisite, the machining program is not executed. This prevents errors during the execution of the machining program and the resulting incorrect machining of the workpiece or damage to the processing machine. The machining program is only executed if the prerequisite is met by the state.

[0010] In one embodiment, a machine operator is notified via a user output when the first requirement of the first state is not met. This allows the machine operator to react to the deviation and establish a state that meets the requirement or load a machining program with different requirements.

[0011] In one embodiment, an image quality of the first image, in particular an image quality that is insufficient for determining the first state, is determined, wherein at least one travel movement of the machining head is carried out and at least one second image of the first machine unit is captured with the camera in at least one further recording perspective if the image quality of the first image is insufficient for determining the first state, wherein the first state of the first machine unit is determined based on the second image. Production conditions, such as light reflections or contamination, often make sensory, in particular camera-based, recordings more difficult. Likewise, even without additional environmental influences, the sensor values ​​as such, in particular camera recordings, can already have a quality that is insufficient for the necessary recording.The disclosed method solves this problem by allowing the camera attached to the machining head of the processing machine to perform at least one further capture of the machine unit by moving the machining head to at least one additional recording perspective. The second image can be used instead of the first image to determine the first state. Alternatively, the second image can be used in combination with the first image to determine the first state.

[0012] In one embodiment, at least one machine unit of the plurality of machine units consists of a magazine with a plurality of machining head tools, in particular machining head tools in the form of nozzles for laser machining or punching heads for punching, wherein each of the machining head tools is inserted in the magazine at a fixed magazine position, wherein the first prerequisite of the first machine machining program comprises the presence of a predetermined machining head tool, wherein the existing machining head tools are detected as a first state, wherein the machining head tools have an identification coding, in particular in the form of a QR code, a barcode and / or an identification number, wherein the identification codings are detected with the camera and the first state is determined from the detected identification codings.

[0013] Tools are a fundamental machine unit of a processing machine. Such tools are typically attached to the processing head of the processing machine. Examples include processing head tools in the form of nozzles for laser processing or punching heads for punching. Such processing head tools are typically interchangeable, and several processing head tools are stored in a magazine in a specific magazine position. If the machine processing program requires at least one processing head tool, information about this can be stored in a machine control system. By moving the processing head, the camera can capture an identification code for a particular processing head tool in a specific magazine position. Information about the captured processing head tool can be passed on to the machine control system.In other words, the method enables mechanical and automated identification of machining head tools in specific magazine positions.

[0014] Furthermore, the method can be used to compare the identified machining head tools with the required machining head tools from the first machining program before its execution, whereby a machining head tool required for the first machining program is identified as missing in the magazine and / or a machining head tool is identified in the magazine that is not required for the first machining program. The method thus enables mechanical and automated identification of missing or incorrectly inserted machining head tools.

[0015] In one embodiment, the magazine position of the predetermined machining head tool is determined, wherein the magazine position of the predetermined machining head tool is taken into account during the execution of the first machining program, in particular during an automatic exchange process of the machining head tool. By taking the magazine position of the predetermined machining head tool into account, the machining program can be adapted to the magazine position. It is therefore not necessary for the predetermined machining head tool to be located at a predetermined magazine position. If the processing machine has a function for an automatic exchange process of the machining head tool, the information about the magazine positions can be passed on to the function for the automatic exchange process.In other words, the process enables mechanical and automated identification and subsequent replacement of machining head tools.

[0016] In one embodiment, the first state is compared with a first prerequisite of a plurality of machining programs, whereby only those machining programs are executed whose first prerequisite is met by the first state. This embodiment is particularly advantageous for a production plan consisting of a plurality of machining programs and stored in a machine control system.

[0017] In one embodiment, manual operator intervention in the processing machine is detected, and after the operator intervention has been completed, the process steps of the machine inspection process are performed again. Such detection can be performed, for example, by sensors in the entrance area of ​​a magazine, for example, by optical sensors in the form of light barriers. After the detected operator intervention has been completed, a re-identification of all machining head tools inserted in the magazine and a comparison with the required machining head tools from the machine processing program or from the machine processing programs of the production plan can be performed.The previously described process steps for identifying missing or incorrectly inserted machining head tools and / or issuing an error message about them and / or comparing them with a production plan can then be initiated again after operator intervention.

[0018] In one embodiment, the first requirement comprises a working area of ​​the processing machine that is free of foreign objects. Before and / or during execution of the first machining program, the first image of the working area of ​​the processing machine is created using the camera. Based on the first image, the first status is determined as to whether a foreign object is in the working area. A foreign object can, for example, be a reject element. A recurring problem when machining workpieces with processing machines is reject elements, which often inevitably arise, particularly during separating process steps such as laser cutting or punching. It is often not possible to prevent reject elements from becoming caught in the machining space between a tool and a workpiece to be machined.However, if such reject elements become trapped in the machining area prior to a planned workpiece processing operation, this can affect the machining quality and / or machining conditions. For example, during laser cutting or punching operations, reject elements in the form of punched or cut-out inner contour parts can remain on a raw material sheet if they were not correctly ejected due to errors. If these reject elements are located on a planned punching or cutting contour, the parameters planned by the machining program for this punching or cutting contour lead to a different and possibly undesirable result or undesirable quality.The disclosed method solves this problem in that, for the machining program to be carried out in a working area of ​​the machine, in particular for laser cutting and / or punching, partial profiles to be traversed for this purpose, in particular laser cutting contours and / or punching forming areas, are detected by a movement of the machining head before and / or during and / or after partial profile machining by means of the camera attached to it, wherein reject elements already located on these partial profiles and / or reject elements arising during workpiece machining are detected and information about this is transmitted to the machine control system.

[0019] Information about the detected foreign object can be output to a user via a user output. This allows the user to react to the foreign object in the work area and initiate appropriate measures. Furthermore, a detected foreign object can trigger a stop of the processing machine.

[0020] As an alternative to the stop, the first machine program can be adjusted. Based on the location of the detected foreign object, machining at this location can be omitted. In other words, part of the first machine processing program is skipped. This, in particular, prevents a collision with the foreign object. Information about the omitted machining can be transmitted to a higher-level production planning system. For example, a workpiece part to be separated that was planned in the machine processing program can be omitted and information about this can be transmitted to a higher-level production planning system, wherein a subsequent machine processing program is expanded by the production planning system to include a new loading of the omitted workpiece part. In other words, the invention enables automated rescheduling of a machining operation disrupted by a foreign object.This is particularly advantageous when a processing machine is operated unmanned for a longer period of time, for example during a night shift.

[0021] In one embodiment, the first requirement comprises the correct ejection of a material part, in particular a remnant or a workpiece part, separated from a raw material to be processed, in particular a sheet metal panel, during the execution of the first machining program. An image of the material part is created using the camera, and based on the image, it is determined as a first status whether the correct ejection has occurred. The function of an automated ejection can, for example, comprise the targeted collection of remnants or separated workpiece parts at a specific location, such as in a storage box located beneath the work area.

[0022] In one embodiment, the first status is determined by a comparison with an additional sensor system for detecting correct ejection. For processing machines that have additional sensors for detecting correct ejection and / or incorrect ejection and / or jamming, the method can be used to further detect the correct ejection and / or incorrect ejection and / or jamming using the camera located on the processing head and to perform a comparison with the additional sensor system, for example, initiated by the additional sensor system detecting unclear or faulty states. Likewise, a combination of the detection by the camera attached to the processing head and the detection by the additional sensor system can be combined to create an overall detection with higher overall quality.

[0023] In one embodiment, the processing machine comprises a processing support, in particular a sheet metal support grid, wherein the first prerequisite comprises a state of the processing support, in particular a slag build-up, wherein a first image of the processing support is created with the first camera and the state of the processing support is determined as the first status based on the image. The state of the processing support can be, for example, sufficient cleanliness and / or flatness. After a longer period of time, processing residues or other process materials can accumulate on such processing supports. If the amount of accumulation exceeds a critical value, this can influence the quality of the workpiece processing. Furthermore, if this target state of the processing support is not met, the method can transmit information about this to the user via the user output.In addition, the process can trigger a stop of the processing machine if the target state of the processing support is undershot.

[0024] In one embodiment, a plurality of workpiece parts are machined during the execution of the first machining program, wherein the first prerequisite is a target quality of a first workpiece part. After machining the first workpiece part, an actual quality of the first workpiece part is recorded as the first state. The cutting edge quality can include properties such as roughness, discoloration, and / or burr formation. If the actual quality falls below the target quality, information about this can be transmitted to the user via the user output.

[0025] Optionally, if the actual quality falls below the target quality, the processing machine can be stopped.

[0026] Also disclosed is a system for carrying out a machine inspection method, comprising a processing machine for processing workpieces, in particular a laser and / or punching processing machine, and a computer unit, wherein the processing machine comprises a processing head and a camera is attached to a processing head of the processing machine, wherein the computer unit is configured to carry out a machine inspection method.

[0027] Further advantages and advantageous embodiments of the subject matter of the invention will become apparent from the description, the claims, and the drawings. Likewise, the above-mentioned and further listed features can be used individually or in combination. The embodiments shown and described are not to be understood as an exhaustive list, but rather as examples for describing the invention.

[0028] They show:

[0029] Fig.1 A system for carrying out a machine inspection method; and

[0030] Fig 2 another system for carrying out a machine inspection procedure.

[0031] Fig. 1 shows a system for carrying out a machine inspection method. The system comprises a processing machine 1, in this case a laser cutting machine. The processing machine 1 is configured to process a workpiece 9, in this case a sheet metal panel. The machine tool 1 comprises a movable processing head 4, in this case a laser cutting head. A camera 3 is attached to the processing head 4. The processing machine 1 comprises a plurality of machine units 2, in this case a magazine 2a, wherein the magazine has six magazine positions 2c, wherein one magazine position 2c is empty and the other five magazine positions 2c are filled with several processing head tools 2b, and a processing support 2d. By moving the processing head 4, the camera 3 can be aligned with the individual machine units 2. In this example, several possible positions of the processing head 4 are shown.The camera 3 can be aligned with the machining support 2d or with the magazine 2a, with the magazine positions 2c and the machining heads 2b. A first image 5 of the machine unit 2 can be created using the camera 3. The system comprises a computing unit 7, wherein the computing unit 7 is communicatively connected to the camera 3. In this example, the computing unit 7 is a computer connected to the processing machine 1. The computing unit 7 can also be part of the processing machine 1. The camera 3 transmits the first image 5 to the computing unit 7. A first machining program 6 and a first prerequisite are stored in the computing unit 7. In this example, the machining program 6 contains the first prerequisite. The computing unit 7 determines a first state of the machine unit 2 from the first image 5 and compares the first state with the first prerequisite of the first machining program 6.If the first state fulfills the first requirement, the machining program 6 is executed by the machining machine 1. The computing unit 7 is connected to a user output 8. If the first state does not fulfill the first requirement, the first machining program 6 is not executed, and information is output via the user output 8 so that a machine operator can react to the faulty state of the machine unit.

[0032] The computing unit 7 checks whether the image quality of the first image 5 is sufficient to determine the first state. For example, the first image 5 may have insufficient image quality due to light reflection or contamination of the optics of the camera 3. If the first image 5 has insufficient image quality, the machining head 4 is moved so that the camera 3 views the first machine unit 2 from a different angle and creates a second image of the first machine unit 2. The state of the first machine unit 2 is then determined based on the second image. By moving the machining head 4, the camera 3 can be aligned with the magazine 2a. The camera 3 then creates an image 5 of the magazine 2a with the magazine positions 2c and the machining head tools 2b located therein.Image 5 is transmitted to the processing unit 7, and the processing unit uses the image 5 to determine which magazine positions 2c are empty and which magazine positions 2c contain a machining head tool 2b. The machining head tools 2b each have an identification code. Based on the identification code, the processing unit 7 determines which machining head tools 2b are present at which magazine positions 2c of the magazine 2a. The processing unit 7 compares the existing machining head tools 2b with the machining head tool presumed in the first machining program 6. If the presumed machining head tool is present in the magazine, the first machining program 6 is executed.If the required machining head tool is not present in the magazine, the first machining program 6 is not executed and information is output to the machine operator via the user output 8.

[0033] The magazine position 2c of the required machining head tool 2b is taken into account when executing the machining program 6. In particular, in the case of an automated exchange process of the machining head tool 2b, the magazine position 2c can be taken into account when executing the machining program 6.

[0034] If multiple machining programs 6 are present in the computing unit 7, the computing unit 7 can compare the state of the first machine unit 2 with the respective first requirements of the machining programs 6. Then, the machining programs 6 whose requirements are met by the state of the first machine unit 2 are executed.

[0035] By further moving the machining head 4, the camera 3 is aligned with the machining support 2d. Using the camera 3, an image 5 of the machining support 2d is then created. The image 5 is transmitted to the computing unit 7, and the computing unit determines from the image 5 whether the state of the machining support 2d fulfills the requirements of the machining program 6. If the state of the machining support 2d fulfills the requirements, the first machining program 6 is executed. If the state of the machining support 2d does not fulfill the requirements, the first machining program 6 is not executed, and information is output to the machine operator via the user output 8.

[0036] The first prerequisite of the machining program 6 can be a required machining head tool, several required machining head tools, a required state of the machining support or any combination thereof.

[0037] Figure 2 shows another system for executing a machine inspection method. Only the differences from Figure 1 are described below. In this example, the computing unit 7 is part of the processing machine 1. Likewise, the user output 8 is part of the processing machine 1.

[0038] By moving the processing head 4, the camera 3 can be aligned with a severed material part 10 or the remaining defect in the workpiece 9. The camera 3 then creates an image 5 of the severed material part 10 and / or the defect in the workpiece 9. The image 5 is transmitted to the computing unit 7, and the computing unit determines from the image 5 whether the severed material part 10 was correctly ejected. In an embodiment not shown, correct ejection can also be checked by further sensors, e.g., a light grid below the workpiece 9. The computing unit 7 compares the state of the severed material part 10 with the prerequisite of the first machining program 6. If the severed material part 10 has been correctly ejected, the first machining program 6 is executed.If the separated material part 10 is not correctly ejected, the first machine processing program 6 is not executed and information is output to the machine operator via the user output 8.

[0039] By moving the machining head 4, the camera 3 can be aligned to different points on the workpiece 9. Images 5 of the workpiece 9 are then created using the camera 3. The images 5 are transmitted to the computing unit 7, and the computing unit determines from the images 5 whether a foreign object 11 is on the workpiece. The computing unit 7 compares the condition of the workpiece 9 with the prerequisite of the first machining program 6. If the workpiece 9 is free of foreign objects 11 that would interfere with the execution of the first machining program 6, the first machining program 6 is executed. If the computing unit 7 detects interfering foreign objects 11 on the workpiece 9, the first machining program 6 is not executed, and information is output to the machine operator via the user output 8.

[0040] Reference symbol

[0041] 1 processing machine

[0042] 2 machine units

[0043] 2a Magazine 2b Machining head tool

[0044] 2c Magazine position

[0045] 2d processing support

[0046] 3 Camera

[0047] 4 Processing head 5 Image

[0048] 6 Machining program

[0049] 7 Computing unit 7

[0050] 8 User output

[0051] 9 Workpiece 10 Separated material part

[0052] 11 Foreign object

Claims

Patent claims 1. Machine inspection method for carrying out checks on a processing machine (1), in particular on a laser and / or punching processing machine, for processing workpieces (9), wherein the processing machine (1) has a plurality of machine units (2), wherein the processing machine (1) has a movable processing head (3), wherein a camera (4) is attached to the processing head (3), wherein a first image (5) of a first machine unit (2) of the plurality of machine units (2) is created with the camera (4), wherein based on the first image (5), a first state of the first machine unit (2) is determined, wherein the first state is compared with at least one first prerequisite for a first machine processing program (6), in particular a laser cutting and / or punching processing program, wherein the first machine processing program (6) is executed,if the first condition is fulfilled by the first state.

2. Machine inspection method according to claim 1, characterized in that a machine operator is informed via a user output (8) if the first requirement of the first state is not met.

3. Machine inspection method according to claim 1 or 2, characterized in that an image quality of the first image (5), in particular an image quality insufficient for determining the first state, is determined, wherein at least one travel movement of the processing head (3) is carried out and at least one second image (5) of the first machine unit (2) is captured with the camera (4) in at least one further recording perspective if the image quality of the first image (5) is insufficient for determining the first state, wherein the first state of the first machine unit (2) is determined based on the second image (5).

4. Machine inspection method according to one of the preceding claims, characterized in that at least a first machine unit (2) of the plurality of machine units (2) consists of a magazine (2a) with several machining head tools (2b), in particular machining head tools (2b) in the form of nozzles for laser machining or punching heads for punching, wherein each of the machining head tools (2b) is inserted in the magazine (2a) at a fixed magazine position (2c), wherein the first prerequisite of the first machine machining program (6) comprises the presence of a predetermined machining head tool (2b), wherein the existing machining head tools (2b) are detected as a first state, wherein the machining head tools (2b) have an identification coding, in particular in the form of a QR code, a barcode and / or an identification number, wherein the identification codings are detected with the camera (4) and the first state is determined from the detected identification codings.

5. Machine inspection method according to claim 4, characterized in that the magazine position (2c) of the predetermined machining head tool (2b) is determined, wherein the magazine position (2c) of the predetermined machining head tool (2b) is taken into account during the execution of the first machine machining program (6), in particular during an automatic exchange process of the machining head tool (2b).

6. Machine inspection method according to one of the preceding claims, characterized in that the first state is compared with a respective first prerequisite of a plurality of machine processing programs (6), wherein only those machine processing programs (6) are executed whose first prerequisite is fulfilled by the first state.

7. Machine inspection method according to one of the preceding claims, characterized in that a manual operator intervention in the processing machine (1) is detected and after the operator intervention has been completed, the method steps of the machine inspection method are carried out again.

8. Machine inspection method according to one of the preceding claims, characterized in that that the first requirement comprises a working area of ​​the processing machine (1) that is free of foreign objects, wherein the first image (5) of the working area of ​​the processing machine (1) is created by means of the camera (3) before and / or during the execution of the first machine processing program (6), wherein, based on the first image (5), it is determined as a first status whether a foreign object (11) is in the working area.

9. Machine inspection method according to one of the preceding claims, characterized in that the first prerequisite comprises a correct ejection of a material part (10), in particular a leftover piece or a workpiece part, which has been separated from a workpiece (9), in particular a sheet metal panel, during the execution of the first machining program (6), wherein an image (5) of the material part is created by means of the camera (3) and based on the image (5) it is determined as a first status whether the correct ejection has taken place.

10. Machine inspection method according to claim 9, characterized in that the first status is determined by a comparison with another sensor system for detecting the correct ejection.

11. Machine inspection method according to one of the preceding claims, characterized in that the processing machine (1) comprises a processing support (2d), in particular a sheet metal support grid, wherein the first prerequisite comprises a state of the processing support (2d), in particular a slag build-up, wherein a first image (5) of the processing support (2d) is created with the first camera (3) and the state of the processing support (2d) is determined as a first status based on the image.

12. Machine inspection method according to one of the preceding claims, characterized in that during the execution of the first machine processing program (6) a plurality of workpiece parts are machined, wherein the first prerequisite is a target quality of a first workpiece part, wherein after the machining of the first workpiece part an actual quality of the first workpiece part is recorded as a first state.

13. System for carrying out a machine inspection method according to one of the preceding claims, consisting of a processing machine (1) for processing workpieces (9), in particular a laser and / or punching processing machine, and a computer unit (7), wherein the processing machine (1) comprises a processing head (4) and a camera (3) is attached to the processing head (4) of the processing machine (1), wherein the computer unit (7) is set up to carry out a machine inspection method according to one of the preceding claims.

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