Generation source identification system and generation source identification method

Abstract

[Problem] To provide a generation source identification system with which a generation source can be efficiently identified. [Solution] A generation source identification system identifies a generation source of chips from a plurality of machining steps for machining a workpiece. The generation source identification system comprises: a database unit in which various data relating to the characteristics of chips generated in each machining step is stored for each machining step; and an acquired data input unit which inputs acquired data relating to the characteristics of chips acquired from a workpiece after machining. The generation source identification system comprises an identification unit that identifies, on the basis of the acquired data input by the acquired data input unit and the various data stored in the database unit, a machining step that is a candidate for a generation source of the chips acquired from the workpiece. The generation source identification system comprises a display unit that displays the machining step identified by the identification unit.

Description

Generation source identification system and method

[0001] The present invention relates to a generation source identification system and a method for identifying a generation source.

[0002] Patent Document 1 discloses a deposit removing device. The deposit removing device inspects the presence or absence of chips and cleans the surface of the workpiece by a cleaning unit.

[0003] Japanese Utility Model Laid-Open No. 4-098540

[0004] In a factory or the like, after processing, an appearance inspection of the workpiece is performed. When chips are found, the chips are removed manually to ensure the quality of the product.

[0005] However, the chips detected by the appearance inspection can pose a quality risk in subsequent processes. Therefore, in order to further improve the quality level of the product, it is desirable not only to take measures to prevent the product with chips attached from being sent to the subsequent process, but also to identify the generation source of the chips and take countermeasures.

[0006] The present invention has been made in view of the above problems, and an object thereof is to provide a generation source identification system that enables efficient identification of a generation source.

[0007] According to an aspect of the present invention, there is provided a generation source identification system for identifying the generation source of chips from a plurality of processing steps for processing a workpiece, the system including: a database unit in which specification data regarding the characteristics of chips generated in each of the processing steps is stored for each of the processing steps; an acquisition data input unit for inputting acquisition data regarding the characteristics of chips obtained from the workpiece after processing; a specifying unit for specifying, based on the acquisition data input to the acquisition data input unit and the specification data stored in the database unit, the processing step that is a candidate for the generation source of the chips obtained from the workpiece; and a display unit for displaying the processing step specified by the specifying unit.

[0008] In one embodiment of the present invention, when chips are found in a workpiece after processing, the chip source identification system receives acquired data regarding the characteristics of the chips obtained from the workpiece. The source identification system then identifies a processing step that is a candidate for the source of the acquired chips based on the input acquired data and the specification data stored in the database, and displays the identified processing step.

[0009] This allows the operator to identify the source of chips found in the processed workpiece from multiple processing steps based on the displayed processing steps.

[0010] Therefore, when chips are found in a workpiece after processing, it becomes possible to efficiently identify the source of the chips compared to when the source must be manually located within a production line with multiple processing steps. Furthermore, since the shape of the chips depends on the conditions of the production line (workpiece material, tool life, etc.), the time from when chips are detected in visual inspection to when the source is identified is extremely important, but it becomes possible to efficiently identify the source and shorten that time.

[0011] Figure 1 is a block diagram of the source identification system according to this embodiment. Figure 2 is an explanatory diagram showing the characteristics of the chips. Figure 3 is an explanatory diagram showing the specifications data. Figure 4 is a flowchart showing the operation of the source identification system. Figure 5 is a flowchart following Figure 4. Figure 6 is a flowchart following Figure 5. Figure 7 is a diagram showing an example of the input screen displayed on the display unit. Figure 8 is a diagram showing an example of the input screen following Figure 7.

[0012] The following describes the source identification system 10 and source identification method according to the present invention with reference to the attached drawings. Figure 1 is a block diagram of the source identification system 10 according to this embodiment.

[0013] As shown in Figure 1, the source identification system 10 according to this embodiment is installed, for example, in a factory production line. The source identification system 10 is a system that identifies the source of chips 20 (see Figure 2) from multiple processing steps that process a workpiece. Examples of workpieces include automobile transmission parts.

[0014] In this embodiment, the source identification system 10 and the source identification method are described using the example of their use in a production line for manufacturing automobile transmission parts, but the invention is not limited to this. The source identification system 10 and the source identification method may also be used in production lines for manufacturing other products.

[0015] The transmission components, as workpieces, are made of aluminum, for example. The workpieces are manufactured through multiple machining processes. These machining processes include cutting or drilling. The chips 20 generated during the machining processes are removed from the workpiece in a cleaning process that follows the machining process, but occasionally they may remain on the workpiece.

[0016] Therefore, the processed workpiece undergoes a visual inspection before being moved to a subsequent process such as the assembly process. If chips 20 are found during the visual inspection, the found chips 20 are removed from the workpiece.

[0017] In this embodiment, if chips 20 are found during visual inspection, the source of the found chips 20 is identified, and countermeasures are taken according to the source to improve the efficiency of chip removal 20.

[0018] The source identification system 10 is centered around a controller 12. The controller 12 is connected to an input unit 14, a database unit 16, and a display unit 18.

[0019] (Controller) The controller 12 controls the operation of the source identification system 10 to perform the source identification method.

[0020] The controller 12 is composed of a computer equipped with a CPU, RAM, ROM, input / output interfaces, etc. The controller 12 performs various processes by having the CPU read and execute programs stored in the ROM. The controller 12 can also be composed of multiple computers.

[0021] The CPU of the controller 12 operates according to a program stored in the ROM, and the source identification system 10 receives acquired data regarding the characteristics of the chips 20 obtained from the workpiece after processing (acquired data input unit, acquisition process). The source identification system 10 then identifies a processing process that is a candidate for the source of the chips 20 obtained from the workpiece, based on the input acquired data and the specification data 22 stored in the database unit 16 (identification unit, identification process). Furthermore, the source identification system 10 displays the identified processing process on the display unit 18 (display process).

[0022] (Input Unit) The input unit 14 consists of a keyboard, mouse, touch panel, etc., connected to the controller 12. By operating the input unit 14, the operator can input data or commands and other operation details to the controller 12.

[0023] This allows the operator to input acquired data regarding the characteristics of the chips 20 obtained from the processed workpiece to the controller 12 via the input unit 14.

[0024] (Display Unit) The display unit 18 consists of a display connected to the controller 12.

[0025] The display unit 18 displays the data from the controller 12 in a visible manner. The operator can recognize the displayed content by visually viewing the content displayed on the display unit 18.

[0026] As a result, when a processing step that is a candidate for the source of chips 20 obtained from the workpiece is displayed on the display unit 18, the operator can recognize the processing step that is a candidate for the source.

[0027] (Database Unit) The database unit 16 consists of a storage device connected to the controller 12. The storage device consists of an internal type device such as a hard disk drive or solid state drive, or an external type device such as a USB memory stick.

[0028] The database unit 16 is capable of reading and writing data. The database unit 16 stores specification data 22 (see Figure 3) regarding the characteristics of the chips 20 generated in each machining process for each machining process.

[0029] The operator can input the specification data 22 from the input unit 14 to the controller 12, thereby storing the specification data 22 in the database unit 16 via the controller 12. The controller 12 can also read the specification data 22 stored in the database unit 16.

[0030] If the database unit 16 is configured as an external storage device, the operator can connect the database unit 16 to another device and use that other device to read and write the specification data 22 stored in the database unit 16. Therefore, if the database unit 16 is configured as an external storage device, the specification data 22 can be moved to and used on another device.

[0031] In a network environment where multiple production line source identification systems 10 and database units 16 are connected via a network, the network environment may be used to manage, for example, specification data 22.

[0032] Here, the chips 20 generated during the machining process and the contents stored in the database unit 16 will be explained in detail using drawings. Figure 2 is an explanatory diagram showing the characteristics of the chips 20. Figure 3 is an explanatory diagram showing the specification data 22.

[0033] (Chip Shape) As shown in Figure 2, the shape of the chips 20 generated in each machining process of the production line differs depending on the machining tool 30 used. Examples of machining tools 30 include milling cutters, drills, reamers, end mills, taps, etc. Examples of chip shapes 32 of the chips 20 generated in the machining process include square, triangular, linear, and granular shapes.

[0034] The shape 32 of the chips 20 generated varies depending on the machining tool 30 used. For example, a milling cutter generates square-shaped chips 20, a drill generates triangular-shaped chips 20, and a reamer generates linear chips 20. Therefore, the machining tool 30 used can be inferred from the shape of the chips 20 obtained from the workpiece.

[0035] (Chip radius) The chip radius 34 of the generated chips 20 is determined according to the diameter of the machining tool 30 used. The chip radius 34 is half the tool diameter of the machining tool 30.

[0036] Specifically, a machining tool 30 with a tool diameter of 5.0 mm generates chips 20 with a chip radius 34 of 2.5 mm. An example of a machining tool 30 with a tool diameter of 5.0 mm is a drill bit with a diameter of 5.0 mm. The diameter of the machining tool 30 used can be estimated from the chip radius 34 obtained from the workpiece.

[0037] (Appearance of chips) Furthermore, the appearance 36 of the generated chips 20 is determined according to the material of the machining tool 30 used. Examples of materials for the machining tool 30 include cemented carbide or diamond.

[0038] The machining tools 30 include cemented carbide tools made of cemented carbide, diamond tools made of diamond, and composite tools made of cemented carbide and diamond. Examples of composite tools include drill bits in which the central part is made of cemented carbide and the outer circumference that cuts the outside of the machining area is made of diamond.

[0039] Chips 20 cut with cemented carbide are gray in color. Chips 20 cut with diamond are shiny.

[0040] A cemented carbide tool made of cemented carbide generates gray chips 20. A diamond tool made of diamond generates shiny chips 20. A composite tool made of cemented carbide and diamond generates chips 20 that include gray parts 36A and shiny parts 36B. Therefore, the material of the machining tool 30 used can be inferred from the appearance of the chips 20 obtained from the workpiece.

[0041] Specifically described, the processing tool 30 that generates the swarf 20A having a triangular shape with the top side being the gray portion 36A and the bottom side being the glossy portion 36B is found to be the cutting edge of a drill formed with a cemented carbide at the center and a diamond at the outer periphery.

[0042] (Swarf thickness) The swarf thickness 38 of the generated swarf 20 is determined according to the cutting conditions. The swarf thickness 38 of the swarf 20 increases as the cutting feed rate increases. Also, the swarf thickness 38 of the generated swarf 20 increases according to the cutting depth.

[0043] As an example, when the cutting feed rate indicating the feed per edge by a milling cutter is 0.1 mm / rev × edge, the swarf 20 has a swarf thickness 38 of 0.080 mm. Here, the feed per edge is determined by the feed rate of the table or column, quill per minute, the rotational speed of the spindle, and the number of edges.

[0044] Therefore, the cutting conditions of the used processing tool 30 can be estimated from the swarf thickness 38 of the swarf 20 obtained from the workpiece.

[0045] (Stored content) Next, the stored content stored in the database unit 16 will be described.

[0046] As shown in FIG. 3, in the database unit 16, the specification data 22 regarding the characteristics of the swarf 20 generated in each processing step is stored for each processing step. The specification data 22 is data corresponding to the characteristics of the swarf 20 generated when processed with the processing tool 30 used for each processing step.

[0047] The specification data 22 is data input from the input unit 14 to the database unit 16 of the generation source identification system 10 by analyzing the swarf 20 collected in advance from each processing step of the production line.

[0048] The specification data 22 includes at least one of a swarf material 40 indicating the material of the swarf 20, a swarf shape 32 indicating the shape of the swarf 20, a swarf radius 34 indicating the radius of the swarf 20, a swarf color tone 42, a presence or absence of gloss 44 indicating the gloss of the swarf 20, or a swarf thickness 38 indicating the thickness of the swarf 20. The swarf color tone 42 and the presence or absence of gloss 44 of the swarf 20 are handled as a swarf appearance 36.

[0049] The process information 50 indicating information on the processing steps includes a processing position 52 to be processed in each processing step and a tool number 54 of the processing tool 30 used in each processing step. The process information 50 can include cutting conditions in each processing step or past defect information.

[0050] Specifically, the specification data 22 is stored in the database unit 16 in a state aggregated as a data table. In the data table aggregating the specification data 22, a process number column 60 storing the processing steps, a swarf material column 62 storing the swarf material 40 as the specification data 22, and a swarf shape column 64 storing the swarf shape 32 as the specification data 22 are set. Also, in the data table aggregating the specification data 22, a swarf radius column 66 storing the swarf radius 34 as the specification data 22 and a swarf appearance column 68 storing the swarf appearance 36 as the specification data 22 are set.

[0051] Also, in the data table aggregating the specification data 22, a swarf thickness column 70 storing the swarf thickness 38 as the specification data 22 is set. Also, in the data table aggregating the specification data 22, a processing position column 72 storing the processing position 52 as the process information 50 and a tool number column 74 storing the processing position 52 as the process information 50 are set.

[0052] The processing steps stored in the process number column 60 are indicated by numbers, and the numbers described in the process number column 60 indicate the process numbers 78 of the processing steps.

[0053] In the data table aggregating the specification data 22, the swarf material 40, the swarf shape 32, the swarf radius 34, the swarf appearance 36, the swarf thickness 38, the processing position 52, and the tool number 54 are stored for each process number 78.

[0054] The chip material column 62 stores strings such as "aluminum" indicating the material of the transmission part being worked, "iron" indicating the material of other parts, and "other" indicating other materials. The chip shape column 64 stores chip shapes 32 to identify the type of machining tool 30. The chip shape 32 is indicated by strings such as "square," "triangular," "linear," and "granular."

[0055] The chip radius column 66 stores the chip radius 34 numerically to identify the diameter of the machining tool 30. The chip appearance column 68 stores the chip appearance 36 to identify the material of the machining tool 30. The chip appearance 36 is indicated by strings such as "gray" indicating the color 42, "glossy" indicating the presence or absence of gloss 44, and "gray + glossy". The chip thickness column 70 stores the chip thickness 38 numerically to identify cutting conditions such as feed rate or depth of cut.

[0056] The machining position column 72 stores the machining positions 52 to be machined in the machining process. The machining positions 52 are indicated by identifiers that have been assigned to them in advance. The tool number column 74 stores the tool numbers 54 of the machining tools 30 used in the machining process. The tool numbers 54 are indicated by identifiers that have been assigned to the machining tools 30 in advance.

[0057] The specification data 22 is created based on chips 20 collected for different usage conditions. In this embodiment, the specification data 22 is created, as an example, based on chips 20 collected for each number of times the workpiece was processed on the production line.

[0058] (Situation-Specific Data) The specification data 22 includes multiple situation-specific data 90 set for different usage situations. The situation-specific data 90 shows the characteristics of the chips 20 which change depending on the usage situation of the machining tool 30.

[0059] The situation-specific data 90 includes data stored according to the number of times a workpiece has been processed on the production line, as well as data stored according to the number of times the processing tool 30 has been used and data stored according to the usage time of the processing tool 30. In this embodiment, as an example, data according to the number of times a workpiece has been processed on the production line is used as the situation-specific data 90.

[0060] The situation-specific data 90 is used differently depending on the usage of the machining tool 30 when identifying the source of the chips 20.

[0061] In other words, the status data 90 by number of processing cycles includes first status data 94 used when the number of processing cycles ranges from "1" to "99". The first status data 94 is data created based on chips 20 collected when the number of processing cycles ranges from "1" to "99".

[0062] The situation-specific data 90 includes second-stage data (not shown) used when the number of processing cycles is in the range of "99" to "499". The second-stage data (not shown) is data created based on chips 20 collected when the number of processing cycles is between "99" and "499".

[0063] The situation-specific data 90 includes third-party situation data 96 used when the number of processing cycles is in the range of "500" to "899". The third-party situation data 96 is data created based on chips 20 collected when the number of processing cycles is between "500" and "899".

[0064] The situation-specific data 90 includes fourth-stage data (not shown) used when the number of processing cycles is in the range of "900" to "1200". The fourth-stage data (not shown) is data created based on chips 20 collected when the number of processing cycles is in the range of "900" to "1200".

[0065] In the first status data 94, in the row for the 30th process where process number 78 is "30", the chip material column 62 contains "aluminum", the chip shape column 64 contains "triangular", and the chip radius column 66 contains "2.5 (mm)". Also, in the first status data 94, in the row for the 30th process where process number 78 is "30", the chip appearance column 68 contains "gray + glossy", and the chip thickness column 70 contains "0.080 (mm)".

[0066] This reveals that the 30th step is a machining process in which a drill with a finishing blade having a tool diameter of 5.0 mm, with a cemented carbide core and a diamond outer edge, is used to drill holes in the aluminum material that makes up the transmission parts.

[0067] Furthermore, in the row for the 30th process where process number 78 of the third status data 96 is "30", the chip material column 62 contains "aluminum", the chip shape column 64 contains "triangular", and the chip radius column 66 contains "2.5 (mm)". Also, in the row for the 30th process where process number 78 of the third status data 96 is "30", the chip appearance column 68 contains "gray + glossy", and the chip thickness column 70 contains "0.100 (mm)".

[0068] Here, the chip radius 34 in the chip radius column 66 does not change much depending on the tool usage. For this reason, the same value is stored in the chip radius column 66 of the first status data 94 and the chip radius column 66 of the third status data 96.

[0069] If the number of machining cycles indicated by the third status data 96 is between 500 and 899, then "0.100 (mm)", which is larger than the value in the first status data 94, is stored in the chip thickness column 70.

[0070] As a result, even if the machining tool 30 wears down with each machining cycle and the chips 20 or chip thickness 38 become large, the database unit 16 stores multiple situation-specific data 90 so that the process number 78 can be identified from the acquired data of the chips 20.

[0071] (Operation Description) Next, the operation of the source identification system 10 will be described with reference to the drawings.

[0072] Figure 4 is a flowchart showing the operation of the source identification system 10. Figure 5 is a flowchart following Figure 4. Figure 6 is a flowchart following Figure 5. Figure 7 is a diagram showing an example of the input screen 100 displayed on the display unit 18. Figure 8 is a diagram showing an example of the input screen 100 following Figure 7.

[0073] In the operation description, when a chip 20 is discovered during a visual inspection, the operator shall input the acquired data regarding the characteristics of the chip 20 found on the production line into the respective fields of the input screen 100 (see Figures 7 and 8) displayed on the display unit 18 via the input unit 14.

[0074] As shown in Figures 4 to 8, when the CPU of the controller 12 operates according to the program stored in the ROM, the controller 12 displays the input screen 100 (see Figures 7 and 8) on the display unit 18 (step S10). The controller 12 also checks the input status of the database unit 16 (step S12).

[0075] Then, the controller 12 checks the data input status to the chip material field 112 on the input screen 100 (step S18) and determines whether or not chip material 40 has been entered into chip material field 112 (step S20). If chip material 40 has not been entered into chip material field 112 in step S20, the controller 12 branches back to step S18.

[0076] If the chip material 40 was entered in step S20, the controller 12 stores the entered chip material 40 in RAM or the like.

[0077] If the input chip material 40 is neither "aluminum" nor "iron", the controller 12 stores in RAM that the chip material 40 is "other" (step S24). If the input chip material 40 is "aluminum", the controller 12 stores in RAM that the chip material 40 is "aluminum" (step S26). If the input chip material 40 is "iron", the controller 12 stores in RAM that the chip material 40 is "iron" (step S28).

[0078] Next, the controller 12 extracts all rows in the specification data 22 in which the input chip material 40 is stored in the chip material column 62 (step S30), and stores the data of all extracted rows as candidate target data in RAM. The controller 12 also displays the process information 50 stored in all extracted rows together with the process number 78 in the candidate target field 130 of the input screen 100 (see Figure 7) (step S32).

[0079] Here, since the transmission parts processed on the production line are made of aluminum, "aluminum" is stored in all rows of the chip material column 62 of the first status data 94. For this reason, at this stage, the candidate target field 130 of the input screen 100 displays the process information 50 stored in all rows of the first status data 94 (not shown).

[0080] Furthermore, if the chips 20 found during the visual inspection are not aluminum, it can be determined that the chips 20 were introduced from outside the production line.

[0081] Then, the controller 12 checks the data input status to the chip shape field 114 on the input screen 100 (step S34) and determines whether or not the chip shape 32 has been entered into the chip shape field 114 (step S36). If the chip shape 32 has not been entered into the chip shape field 114 in step S36, the controller 12 branches back to step S34.

[0082] If the chip shape 32 was entered in step S36, the controller 12 stores the entered chip shape 32 in RAM or the like.

[0083] If the input chip shape 32 is "square," the controller 12 stores in RAM that the chip shape 32 is "square" (step S38). If the input chip shape 32 is "triangular," the controller 12 stores in RAM that the chip shape 32 is "triangular" (step S40). If the input chip shape 32 is "linear," the controller 12 stores in RAM that the chip shape 32 is "linear" (step S42). If the input chip shape 32 is "granular," the controller 12 stores in RAM that the chip shape 32 is "granular" (step S44).

[0084] Next, the controller 12 extracts all rows from the candidate target data stored in RAM in which the input chip shape 32 is stored in the chip shape column 64 (step S46). The controller 12 also updates the candidate target data by storing the data of all extracted rows as candidate target data in RAM. The controller 12 also displays the process information 50 stored in all extracted rows, along with the process number 78, in the candidate target field 130 of the input screen 100 (see Figure 7) (step S48).

[0085] If the first, thirtieth, and forty-fifth steps are extracted from the candidate target data stored in RAM, the process information 50 for the first step, the process information 50 for the thirtieth step, and the process information 50 for the forty-fifth step will be displayed in the candidate target field 130 (see Figure 7) of the input screen 100.

[0086] The controller 12 then checks the data input status to the chip radius field 116 on the input screen 100 (step S50) and determines whether or not the chip radius 34 has been entered into the chip radius field 116 (step S52). If the chip radius 34 has not been entered into the chip radius field 116 in step S52, the controller 12 branches back to step S50.

[0087] If a chip radius 34 was entered in step S52, the controller 12 stores the entered chip radius 34 in RAM or the like.

[0088] If the input chip radius 34 is "1.5", the controller 12 stores in RAM that the chip radius 34 is "1.5" (step S54). If the input chip radius 34 is "2.0", the controller 12 stores in RAM that the chip radius 34 is "2.0" (step S56). If the input chip radius 34 is "2.5", the controller 12 stores in RAM that the chip radius 34 is "2.5" (step S58). If the input chip radius 34 is "3.0", the controller 12 stores in RAM that the chip radius 34 is "3.0" (step S60).

[0089] Next, the controller 12 extracts all rows in the candidate target data stored in RAM where the input chip radius 34 is stored in the chip radius column 66 (step S64). The controller 12 then updates the candidate target data by storing the data of all extracted rows as candidate target data in RAM. The controller 12 also displays the process information 50 stored in all extracted rows, along with the process number 78, in the candidate target field 130 of the input screen 100 (step S66).

[0090] The controller 12 then checks the data input status to the chip appearance field 118 on the input screen 100 (step S70) and determines whether or not the chip appearance 36 has been entered into the chip appearance field 118 (step S72). If the chip appearance 36 has not been entered into the chip appearance field 118 in step S72, the controller 12 branches back to step S70.

[0091] If the chip appearance 36 was entered in step S72, the controller 12 stores the entered chip appearance 36 in RAM or the like.

[0092] If the input chip appearance 36 is "gray", the controller 12 stores in RAM that the chip appearance 36 is "gray" (step S74). Also, if the input chip appearance 36 is "gray + glossy", the controller 12 stores in RAM that the chip appearance 36 is "gray + glossy" (step S76). Also, if the input chip appearance 36 is "glossy", the controller 12 stores in RAM that the chip appearance 36 is "glossy" (step S78).

[0093] Next, the controller 12 extracts all rows from the candidate target data stored in RAM in which the input chip appearance 36 is stored in the chip appearance column 68 (step S80). The controller 12 updates the candidate target data by storing the data of all extracted rows as candidate target data in RAM. The controller 12 also displays the process information 50 stored in all extracted rows together with the process number 78 in the candidate target field 130 of the input screen 100 (step S82).

[0094] The controller 12 then checks the data input status to the chip thickness field 120 on the input screen 100 (step S90) and determines whether or not the chip thickness 38 has been entered into the chip thickness field 120 (step S92). If the chip thickness 38 has not been entered into the chip thickness field 120 in step S92, the controller 12 branches back to step S90.

[0095] If the chip thickness 38 was entered in step S92, the controller 12 stores the entered chip thickness 38 in RAM or the like.

[0096] If the input chip thickness 38 is "0.060", the controller 12 stores in RAM that the chip thickness 38 is "0.060" (step S94). Also, if the input chip thickness 38 is "0.080", the controller 12 stores in RAM that the chip thickness 38 is "0.080" (step S96). Also, if the input chip thickness 38 is "0.100", the controller 12 stores in RAM that the chip thickness 38 is "0.100" (step S98).

[0097] Next, the controller 12 extracts all rows in the candidate target data stored in RAM where the input chip thickness 38 is stored in the chip thickness column 70 (step S100). The controller 12 updates the candidate target data by storing the data of all extracted rows as candidate target data in RAM. The controller 12 also displays the process information 50 stored in all extracted rows, along with the process number 78, in the candidate target field 130 of the input screen 100 (step S102).

[0098] In this way, the controller 12 filters the specification data 22 stored in the database unit 16 in the following order: chip material 40, chip shape 32, chip radius 34, chip appearance 36, and chip thickness 38, which are acquired data obtained from the discovered chips 20. By doing so, the controller 12 narrows down the candidate sources of the discovered chips 20.

[0099] The controller 12 then identifies the candidate data stored in RAM as the final candidate (step S110), and displays the process information 50 of the final candidate data along with the process number 78 on the input screen 100 (step S112).

[0100] Specifically, the controller 12 displays the process number 78 of the candidate data that was selected as the final candidate in the process number display field 134 of the input screen 100. The controller 12 also displays the machining position 52 included in the process information 50 of the candidate data that was selected as the final candidate in the machining position display field 136 of the input screen 100. The controller 12 also displays the tool number 54 included in the process information 50 of the candidate data that was selected as the final candidate in the tool number display field 138 of the input screen 100.

[0101] As shown in Figure 8, if the chip material 40 of the chip 20 found in the visual inspection is "aluminum", it is determined that the found chip 20 was generated in one of the processing steps of an aluminum transmission part being processed on the production line. Furthermore, if the chip shape 32 of the chip 20 found in the visual inspection is "triangular", the chip radius 34 is "2.5" mm, the chip appearance 36 is "gray + glossy", and the chip thickness 38 is "0.080" mm, the candidate sources are narrowed down based on this data.

[0102] From the first status data 94, a row is extracted in which process number 78 is "30", and in which the chip material column 62 is "aluminum", the chip shape column 64 is "triangular", the chip radius column 66 is "2.5", the chip appearance column 68 is "gray + gloss", and the chip thickness column 70 is "0.080". The number in the process number column 60 of the first status data 94 indicates the process number 78 of the processing process, and the number "30" stored in the process number column 60 indicates the 30th process. As a result, the "30th process" indicated by the "30" in process number 78 is considered a candidate for the source of chips 20.

[0103] The "30" indicating the 30th process, which was identified as a candidate source of chips 20, is displayed in the process number display field 134 of the input screen 100. Additionally, "#230 Hole" in the machining position column 72, which indicates the process information 50 for the row where "30" is stored in the process number column 60, is displayed in the machining position display field 136 of the input screen 100. Note that "#230 Hole" is an identifier pre-assigned to the machining position 52 to be machined in the 30th process.

[0104] Furthermore, "Tool 3" in the tool number column 74, which indicates the process information 50 for the row in process number column 60 where "30" is stored, is displayed in the tool number display field 138 of the input screen 100. Note that "Tool 3" is an identifier pre-assigned to the machining tool 30 used for machining in the 30th process.

[0105] In this embodiment, the chip material 40, chip shape 32, chip radius 34, chip appearance 36, and chip thickness 38 were described as acquired data relating to the characteristics of the chip 20, but the acquired data may be increased further. With such a configuration, the accuracy of identifying the source of the chip 20 can be further improved, and it will also be possible to identify the source of the chip 20 in parts other than aluminum parts.

[0106] (Functions and Effects) The main functions and effects of the source identification system 10 and source identification method configured as described above will be summarized below.

[0107] (1) The source identification system 10 is a system that identifies the source of chips 20 from multiple processing steps that process a workpiece. The source identification system 10 includes a database unit 16 in which parameter data 22 relating to the characteristics of the chips 20 generated in each processing step is stored for each processing step. The source identification system 10 includes an acquisition data input unit (14, steps S18, S34, S50, S70, S90) that inputs acquisition data (40, 32, 34, 36, 38) relating to the characteristics of the chips 20 obtained from the workpiece after processing. The source identification system 10 includes an identification unit (steps S30, S46, S64, S80, S100, S110) that identifies a machining process that is a candidate source of chips 20 acquired from a workpiece, based on acquired data (40, 32, 34, 36, 38) input to the acquired data input unit (14, steps S18, S34, S50, S70, S90) and specification data 22 stored in the database unit 16. The source identification system 10 also includes a display unit 18 (steps S32, S48, S66, S82, S102, S112) that displays the machining process identified by the identification unit (steps S30, S46, S64, S80, S100, S110).

[0108] (5) The source identification method is a method for identifying the source of chips 20 from multiple processing steps that process a workpiece. The source identification method includes an acquisition step (steps S18, S34, S50, S70, S90) for acquiring acquired data (40, 32, 34, 36, 38) relating to the characteristics of chips 20 obtained from the workpiece after processing. The source identification method includes an identification step (steps S30, S46, S64, S80, S100, S110) for identifying a processing step that is a candidate for the source of chips 20 obtained from the workpiece, based on the acquired data (40, 32, 34, 36, 38) acquired in the acquisition step (steps S18, S34, S50, S70, S90) and specification data 22 relating to the characteristics of chips 20 generated in each processing step stored in the database unit 16 for each processing step.

[0109] In this embodiment, if chips 20 are found in a workpiece after processing, the source identification system 10 receives acquired data (40, 32, 34, 36, 38) regarding the characteristics of the chips 20 obtained from the workpiece. The source identification system 10 then identifies a processing step that is a candidate for the source of the acquired chips 20 based on the input acquired data (40, 32, 34, 36, 38) and the specification data 22 stored in the database unit 16. The identified processing step is then displayed.

[0110] This allows the operator to identify the source of the chips 20 found in the processed workpiece based on the displayed processing steps (130, 134) from among multiple processing steps.

[0111] To explain in more detail, in step S30, it can be determined that the chips 20 found in the visual inspection originated in a processing step of the production line. Furthermore, the candidate sources of the chips 20 are narrowed down as the process progresses through steps S46, S64, S80, and S100. Finally, in step S110, the candidate sources of the chips 20 are narrowed down, and the processing step that is the source is identified.

[0112] Therefore, when chips 20 are found in a workpiece after processing, it becomes possible to efficiently identify the source of the chips 20 compared to the case where the source of the chips 20 must be manually located from a production line with multiple processing steps.

[0113] Furthermore, the source identification system 10 can identify the source by inputting acquired data (40, 32, 34, 36, 38) regarding the characteristics of the chips 20 obtained from the workpiece. Therefore, even a person without specialized knowledge or experience in identifying sources can identify the source.

[0114] Furthermore, since the source can be identified by inputting predetermined characteristics of the chips 20 (40, 32, 34, 36, 38), detailed analysis of the acquired chips 20 becomes unnecessary. Therefore, compared to the case where a skilled worker with specialized knowledge or extensive experience analyzes the chips 20 in detail to identify the source, the time required to identify the source can be significantly reduced.

[0115] Furthermore, since the source of the chips 20 can be identified in a short time, it becomes possible to investigate the chip generation process without being affected by changes in the chips 20 over time caused by wear of the machining tool 30, etc. This makes it easier to implement measures to address the source of chips 20, such as improving the machining process or the cleaning process to remove the chips 20, thereby reducing the risk of recurrence.

[0116] Since the specification data 22 is stored in the database unit 16, by transferring the specification data 22 to equipment on other production lines, it becomes possible to identify the source of the chips 20 on those other production lines.

[0117] (2) In the source identification system 10, the specification data 22 is data corresponding to the characteristics of the chips 20 generated when processing with the processing tool 30 used for each processing step.

[0118] (6) In the method for identifying the source, the specification data 22 is data corresponding to the characteristics of the chips 20 generated when processed with the processing tool 30 used for each processing step.

[0119] In this embodiment, the specification data 22 is data corresponding to the characteristics of the chips 20 of the machining tool 30 used in each machining process. Therefore, the source identification system 10 can identify the machining process in which the identified machining tool 30 is used as the source by identifying the machining tool 30 from the specification data 22.

[0120] (3) In the source identification system 10, the specification data 22 includes at least one of the following: material (40), shape (32), radius (34), color (42), gloss (44), or thickness (38) of the chips 20.

[0121] (7) In the method for identifying the source, the specification data 22 includes at least one of the following: material (40), shape (32), radius (34), color (42), gloss (44), or thickness (38) of the chips 20.

[0122] According to this embodiment, the data to be input as acquired data can be determined from at least one of the following: material (40), shape (32), radius (34), color (42), gloss (44), or thickness (38) of the chips 20. Therefore, the source identification system 10 can identify the source even when operated by an operator without specialized knowledge or experience.

[0123] (4) In the source identification system 10, the specification data 22 includes multiple situation-specific data 90, which are set for each different usage situation, and which describe the characteristics of the chips 20 that change depending on the usage situation of the machining tool 30.

[0124] (8) In the method for identifying the source, the specification data 22 includes a plurality of situation-specific data 90, each set for different usage conditions, which represent the characteristics of the chips 20 that change depending on the usage conditions of the machining tool 30.

[0125] According to this embodiment, even if the state of the chips generated changes depending on the usage conditions of the machining tool 30, it becomes possible to identify the source of the chips.

[0126] Although embodiments of the present invention have been described above, these embodiments only represent a part of the application examples of the present invention, and are not intended to limit the technical scope of the present invention to the specific configurations of the above embodiments.

[0127] 10 Source Identification System 14 Input Unit 16 Database Unit 18 Display Unit 20 Chips 22 Specification Data 30 Machining Tool 32 Chip Shape 34 Chip Radius 36 Chip Appearance 36A Gray Area 36B Glossy Area 38 Chip Thickness 40 Chip Material 44 Glossiness (Presence / Absence) 50 Process Information 90 Data by Situation 100 Input Screen 134 Process Number Display Field 136 Machining Position Display Field 138 Tool Number Display Field

Claims

1. A chip source identification system for identifying the source of chips from multiple processing steps for processing a workpiece, comprising: a database unit storing parameter data relating to the characteristics of chips generated in each of the processing steps; an acquisition data input unit for inputting acquisition data relating to the characteristics of chips obtained from the workpiece after processing; an identification unit for identifying the processing steps that are candidates for the source of chips obtained from the workpiece based on the acquisition data input unit and the parameter data stored in the database unit; and a display unit for displaying the processing steps identified by the identification unit.

2. A source identification system according to claim 1, wherein the specification data is data corresponding to the characteristics of chips generated when processing with a processing tool used for each processing step.

3. A source identification system according to claim 2, wherein the specification data includes at least one of the material, shape, radius, color, gloss, or thickness of the chips.

4. A source identification system according to claim 3, wherein the specification data includes a plurality of situation-specific data sets, each set for different usage conditions, in which the characteristics of chips change depending on the usage conditions of the processing tool.

5. A method for identifying the source of chips from multiple processing steps for processing a workpiece, comprising: an acquisition step of acquiring acquired data relating to the characteristics of chips obtained from the workpiece after processing; and an identification step of identifying a processing step that is a candidate for the source of chips obtained from the workpiece, based on the acquired data acquired in the acquisition step and specification data relating to the characteristics of chips generated in each of the processing steps stored in a database for each processing step.

6. A method for identifying a source of chips according to claim 5, wherein the specification data is data corresponding to the characteristics of chips generated when processing with a processing tool used for each processing step.

7. A method for identifying a source of chips according to claim 6, wherein the specification data includes at least one of the material, shape, radius, color, gloss, or thickness of the chips.

8. A method for identifying a source of chips according to claim 7, wherein the specification data includes a plurality of situation-specific data sets, each set for different usage conditions, in which the characteristics of chips change depending on the usage conditions of the processing tool.

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