Display device and computer-readable recording medium

Abstract

A display device according to the present disclosure comprises: a simulation result acquisition unit that acquires a simulation result of a non-contact processing element, said simulation result including at least the axis operation of a prescribed non-contact processing device at each block of a processing program and an interpolation area between blocks; a non-contact processing element; a correlation data acquisition unit that acquires correlation data which indicates the correlation with the state of a workpiece processed under the non-contact processing element; a display format setting unit that sets the display format of the simulation result on the basis of the correlation data; and an output unit that outputs the simulation result on the basis of the display format set by the display format setting unit.

Description

Display device and computer-readable recording medium

[0001] The present disclosure relates to a display device and a computer-readable recording medium.

[0002] In machine tools that perform contact machining such as lathes and machining centers, there is a technique for adjusting parameters and performing machining simulation by using the simulation results of axis movements (for example, Patent Document 1, etc.). On the other hand, in non-contact machining using lasers, electrical discharges, water jets, etc., in order to set machining conditions on the drawing board and confirm the machining results in advance, a technique for simulating the machining results when settings related to the energy used for predetermined axis movements and machining are made is required.

[0003] Japanese Patent Application Laid-Open No. 2019-152936

[0004] In non-contact machining, in addition to axis movements, the energy output has a great influence on the machining results. Therefore, simply simulating each machining element does not easily allow one to determine how each machining element affects the state of the workpiece. Even if simulation results are obtained by a conventional display device, it is difficult to grasp the influence of the machining elements on the state of the workpiece from them. In the field, a technique that enables one to grasp the influence of the machining elements on the workpiece from the simulation results of non-contact machining is desired.

[0005] When displaying the simulation results of non-contact machining by a conventional display device, the display device according to the present disclosure solves the above problems by changing the display mode using the correlation between the machining elements and the state of the workpiece.

[0006] Furthermore, one aspect of the present disclosure is a display device comprising: a simulation result acquisition unit that acquires simulation results of non-contact machining elements, including the movement of at least the axis of a predetermined non-contact machining device, in each block and interpolation points between blocks of a machining program; a correlation data acquisition unit that acquires correlation data showing the correlation between the non-contact machining element and the state of a workpiece machined under the non-contact machining element; a display format setting unit that sets the display format of the simulation results based on the correlation data; and an output unit that outputs the simulation results based on the display format set by the display format setting unit.

[0007] This is a schematic hardware configuration diagram of a display device according to the first embodiment of this disclosure. This is a block diagram showing the schematic functions of the display device according to the first embodiment. This is a schematic diagram showing an example of correlation data stored in the correlation data storage unit. This is a schematic diagram showing an example of a machine learning model. This is a schematic diagram showing an example of a processing program that controls the operation of a laser processing machine, which is a non-contact processing device. This is a schematic diagram showing the results of a path simulation. This is a magnified view of a corner of the path simulation results. This is a schematic diagram showing an example of setting the display format of the simulation results. This is a schematic diagram showing another example of setting the display format of the simulation results.

[0008] Embodiments of this disclosure will be described below with reference to the drawings. In the following description, components having the same or similar functions will be denoted by the same reference numerals. Duplication of these components may be omitted.

[0009] In this application, "based on XX" means "based on at least XX," and includes cases where it is based on another element in addition to XX. Furthermore, "based on XX" is not limited to cases where XX is used directly, but also includes cases where it is based on something that has been calculated or processed. "XX" is any element (for example, any information).

[0010] [First Embodiment] Figure 1 is a schematic hardware configuration diagram showing the main parts of a display device according to the first embodiment of the present disclosure. The display device 1 according to this embodiment can be implemented, for example, as a control device that controls industrial machinery based on a control program. The display device 1 according to this embodiment can also be implemented on a personal computer attached to a control device that controls industrial machinery, or on a personal computer, cell computer, fog computer 6, cloud server 7, or other computer connected to the control device via a wired / wireless network 5. In this embodiment, an example is shown in which the display device 1 is implemented on a personal computer connected to a control device 3 that controls industrial machinery via a network 5.

[0011] The CPU 11 in the display device 1 according to this embodiment is a processor that controls the display device 1 as a whole. The CPU 11 reads the system program stored in the ROM 12 via the bus 22 and controls the entire display device 1 according to the system program. The RAM 13 temporarily stores temporary calculation data, display data, and various data input from external sources.

[0012] The non-volatile memory 14 is composed of, for example, a memory backed up by a battery (not shown) or an SSD (Solid State Drive), and its stored state is maintained even when the power to the display device 1 is turned off. The non-volatile memory 14 stores programs and data read from external devices 72 via interface 15, programs and data input from input devices 71 via interface 18, and programs and data acquired from the control device 3 or other devices via network 5. The stored data may include, for example, parameters related to axis movement and energy output set in the control device 3. The programs and data stored in the non-volatile memory 14 may be expanded into RAM 13 during execution / use. In addition, various system programs, such as known analysis programs, are pre-written in ROM 12.

[0013] Interface 15 is an interface for connecting the CPU 11 of the display device 1 to an external device 72 such as a USB device. From the external device 72, for example, system programs, programs related to the operation of the industrial machine 4, and setting data can be read. In addition, programs and setting data created and edited within the display device 1 can be stored in an external storage means via the external device 72.

[0014] Interface 20 is an interface for connecting the CPU 11 of the display device 1 to a wired or wireless network 5. The network 5 may communicate using technologies such as serial communication (RS-485, for example), Ethernet® communication, optical communication, wireless LAN, Wi-Fi®, Bluetooth®, etc. A control device 3 that controls at least one industrial machine 4, a fog computer 6, a cloud server 7, a simulation device 9, etc. are connected to the network 5 and exchange data with the display device 1.

[0015] The display device 70 displays data obtained as a result of the execution of various data, programs, etc., loaded into memory, via the interface 17. The input device 71, consisting of a keyboard and pointing device, transmits commands, data, etc., based on operator operations to the CPU 11 via the interface 18.

[0016] The simulation device 9 simulates the operation of the industrial machine 4, which is a non-contact processing device, and outputs the processing state of the workpiece as a simulation result. Examples of non-contact processing devices that the simulation device 9 can simulate include laser processing machines, laser robots equipped with laser transmitters, processing machines that perform processing using voltage such as die-sinking EDM machines and wire EDM machines, and water jet processing machines that perform processing using water pressure. This simulation calculates the operation of each axis of the target non-contact processing device and the output states of lasers, discharges, water flows, etc., sequentially, and simulates the processing performed on the workpiece. At this time, the simulation device 9 performs simulation processing based on the parameters of the non-contact processing device on which the simulation is performed. The processing related to this simulation may be a general one based on conventional technology. The simulation performed by the simulation device 9 may be, for example, a simple path simulation that calculates the processing path as a simulation result, or a 3D processing simulation that calculates the result of removing polygons from the processed position by the laser, discharge, water flow, etc., from a virtual workpiece formed by polygons, etc. The simulation results calculated by the simulation device 9 may be any combination of data, such as text, graphics, haptics, audio, and video.

[0017] The simulation process performed by the simulation device 9 calculates the axis position of the non-contact processing device and the output of lasers, discharges, water flows, etc., at predetermined intervals based on the results of analyzing the processing program. Based on this, it calculates, from the start to the end of processing, what level of output of lasers, discharges, water flows, etc., is applied to which positions on the workpiece, and how and where those positions on the workpiece are processed. Non-contact processing devices process workpieces by supplying energy to photons, electrons, or fluids without directly contacting the workpiece with tools. The simulation device 9 calculates various values ​​related to the energy expended during processing using photons, electrons, heat, or fluids. In this specification, these various energy-related values ​​are referred to as non-contact processing elements. For example, non-contact processing elements related to workpiece cutting in laser processing machines and laser robots include processing speed, focal position, laser output, frequency, duty cycle, assist gas pressure, and gap amount with the workpiece. Furthermore, non-contact processing elements related to welding workpieces in laser processing machines and laser robots include spatter, burn-through, size of the melted area, height and width of the molten adduct, temperature rise of the workpiece, and amount of reflected light from the workpiece. Non-contact processing elements in electrical discharge machining include processing speed, inter-electrode voltage, average processing current, pulse width, pulse period, and processing fluid pressure. In addition, non-contact processing elements in water jet machining include processing speed, nozzle output pressure, standoff distance, and nozzle diameter. The simulation results calculated by the simulation device 9 include these non-contact processing elements.

[0018] Figure 2 is a schematic block diagram showing the functions of the display device 1 according to the first embodiment of this disclosure. Each function of the display device 1 according to this embodiment is realized by the CPU 11 of the display device 1 shown in Figure 1 executing a system program and controlling the operation of each part of the display device 1.

[0019] The display device 1 according to this embodiment includes a simulation result acquisition unit 110, a correlation data acquisition unit 120, a display format setting unit 130, and an output unit 150. Furthermore, the RAM 13 to non-volatile memory 14 of the display device 1 according to this embodiment is pre-configured with a correlation data storage unit 210, which is an area for storing correlation data showing the correlation between a non-contact processing element in a non-contact processing apparatus and the state of a workpiece processed under the non-contact processing element.

[0020] The simulation result acquisition unit 110 acquires simulation results from a simulation device 9 located outside the display device 1. The simulation result acquisition unit 110 may, for example, acquire simulation results from the simulation device 9 via the network 5 based on a command from the user. Alternatively, it may acquire simulation results from an external computer such as a fog computer 6 or a cloud server 7 via the network 5. Furthermore, it may acquire simulation results from an external device 72. The simulation result acquisition unit 110 outputs the acquired simulation results to the display format setting unit 130.

[0021] The correlation data acquisition unit 120 acquires correlation data showing the correlation between the non-contact processing element in the non-contact processing apparatus and the state of the workpiece processed under the non-contact processing element. The correlation data acquisition unit 120 may also acquire correlation data stored in the correlation data storage unit 210. Alternatively, correlation data may be acquired from an external computer such as a fog computer 6 or a cloud server 7 via the network 5. The state of the workpiece shown by the correlation data may represent various states that can occur in the workpiece as a result of non-contact processing. For example, examples of the state of the workpiece when laser cutting is performed include dross, presence or absence of burrs, inability to cut, density of the cut surface, temperature rise of the workpiece, and amount of reflected light from the workpiece. Also, examples of the state of the workpiece when laser welding, wire electrical discharge machining, or powder melting and addition processing include spatter, melt-off, size of the melting area, height and width of the melted addition, temperature rise of the workpiece, and amount of reflected light from the workpiece. In addition to these, the correlation data may also include other states of the workpiece that can occur in each non-contact processing method.

[0022] The correlation data acquired by the correlation data acquisition unit 120 may be tabular data that enables the determination of the state of the workpiece based on the values ​​of the non-contact processing elements. Figure 3 is a schematic diagram showing an example of correlation data stored in the correlation data storage unit. The example in Figure 3 is a tabular summary of correlation data showing the correlation between non-contact processing elements and the state of the workpiece during laser processing. In the example in Figure 3, for the sake of simplicity, the correlation data is shown to show the correlation between the processing speed and laser output as non-contact processing elements and the state of the workpiece. However, in reality, correlation data showing the correlation between a larger number of non-contact processing elements and the state of the workpiece is used. In the correlation data in Figure 3, for example, it is shown that when processing is performed at a processing speed of 1000 [mm / min] and a laser output of 400 [w], the state of the workpiece at that processing position is that no burrs are generated (symbol A). Also, for example, when processing is performed at a processing speed of 800 [mm / min] and a laser output of 200 [w], it is shown that the state of the workpiece at that processing position is that moderate burrs are generated (symbol C). Correlation data can be created in advance by conducting experiments or other methods to measure the relationship between the non-contact processing element and the state of the workpiece. In addition to managing correlation data in this tabular format, correlation data may also be managed using a machine learning model such as a regression equation or neural network, with the non-contact processing element as the explanatory variable and the state of the workpiece as the dependent variable, as illustrated in Figure 4. The correlation data acquisition unit 120 outputs the acquired correlation data to the display format setting unit 130.

[0023] The display format setting unit 130 sets the display format of the simulation results acquired by the simulation result acquisition unit 110 based on the correlation data acquired by the correlation data acquisition unit 120. The display format setting unit 130 extracts non-contact machining elements from the simulation results. Then, it refers to the correlation data and determines the state of the workpiece corresponding to the non-contact machining element. Then, based on the determination result, it sets the display format for each machining position of the workpiece in the simulation results. The display format setting unit 130 may, for example, set the display format for each machining position of the machining path which is the simulation result. Alternatively, it may, for example, set the display format of the texture at each machining position of a workpiece formed by polygons which is the simulation result.

[0024] The output unit 150 outputs the simulation results based on the display format set by the display format setting unit 130. The output unit 150 may output the simulation results with the set display format as data in any format, such as text, graphics, haptics, audio, or video. The output unit 150 may also display the simulation results with the set display format to the display device 70. Alternatively, it may transmit the output to other computers such as the fog computer 6 or the cloud server 7 via the network 5.

[0025] The output from the output unit 150 will be explained below using Figures 5 to 8. Figure 5 is a schematic diagram showing an example of a processing program that controls the operation of a laser processing machine, which is a non-contact processing device. In the program example in Figure 5, "F1000" is a command to set the movement speed of the processing head, i.e., the processing speed, to 1000 mm / min. Also, "S400" is a command to set the laser output to 400 W. Then, by commanding the X coordinate and Y coordinate following the feed command "G01", the processing head is moved from (X,Y)=(0,0) -> (X,Y)=(200,0) -> (X,Y)=(200,100) -> (X,Y)=(0,100) -> (X,Y)=(0,0) while the laser is outputting.

[0026] Figure 6 is a schematic diagram showing the results of a path simulation obtained by performing a simulation process based on the machining program in Figure 5. As shown in Figure 6, when the laser machining machine is controlled based on the machining program in Figure 5, the machining head moves over the workpiece 300 in a roughly rectangular shape, cutting the workpiece 300 into a roughly rectangular shape. At this time, between the block with sequence number N2 and the block with sequence number N3, between the block with sequence number N3 and the block with sequence number N4, and between the block with sequence number N4 and the block with sequence number N5, speed control is performed in relation to acceleration and deceleration due to changes in the direction of movement (deceleration due to the stopping of movement by the previous block, and acceleration due to the starting of movement by the subsequent block). Therefore, at these corners, the machining path draws a curve that includes an inward curvature error.

[0027] Figure 7 is an enlarged view of the corner between block number N3 and block number N4 in the path simulation results of Figure 6. As illustrated in Figure 7, when moving along a straight line away from the corner in each block, the machining speed is 1000 [mm / min], as commanded by speed command F. On the other hand, when approaching a corner, acceleration and deceleration processing is performed and the movement speed of the machining head decreases. In the example in Figure 7, deceleration begins just before reaching the corner, and the machining speed becomes 800 [mm / min], and near the corner, the machining speed becomes 600 [mm / min]. Then, acceleration begins immediately after leaving the corner, and the machining speed becomes 800 [mm / min]. These machining speeds are sequentially calculated by the simulation device 9 as non-contact machining elements.

[0028] Figure 8 is a schematic diagram showing an example of how the display format setting unit 130 sets the display format for each processing position in the simulation results of Figure 6. In the example of Figure 8, the display format is set so that the display manner of the processing path changes according to the state of the workpiece for each processing position. In Figure 8, a white outline indicates that no burrs have occurred. A vertical line indicates that a small amount of burrs have occurred, and a horizontal line indicates that a moderate amount of burrs have occurred. The display format settings by the display format setting unit 130 are not limited to these examples. For example, different colors may be used depending on the state of the workpiece at each location, or symbols representing the state of the workpiece may be attached, or the display may be replaced with a detailed depiction or gradient depiction representing the state of the workpiece. In addition, although non-contact processing elements included in the simulation results generally have values ​​calculated at discrete positions, a gradient-like display may be performed by interpolating the states between discrete workpiece states obtained from these discrete contact processing elements.

[0029] Figure 9 is a schematic diagram showing another example of setting the display format for simulation results. The example in Figure 9 shows the result of a simulation process that simulates the cross-section of a workpiece after machining by a wire electrical discharge machine using polygons. The display format setting unit 130 sets the display format based on correlation data that shows the correlation between the non-contact machining element and the degree of roughness of the cross-section of the workpiece. In the example in Figure 9, the workpiece is drawn as a collection of polygons as the simulation result, and the display format of the texture attached to the surface of the polygons is set based on the judgment result. In Figure 9, areas of the polygons that are white indicate that no roughness has occurred. Areas of polygons with vertical lines indicate minor roughness, and areas of polygons with horizontal lines indicate moderate roughness. The display format setting by the display format setting unit 130 is not limited to this, and for example, different colors may be used depending on the state of the workpiece at each location, or symbols representing the state of the workpiece may be attached, or textures that represent the state of the workpiece in detail or textures that show gradient depiction may be replaced.

[0030] The display device 1 according to this embodiment, which has the above configuration, allows for more detailed confirmation of the processing results of non-contact machining by setting the display format according to the non-contact machining elements that are affected by the acceleration and deceleration movements of the axis, etc., for the simulation results output by the simulation device 9 that performs a general simulation of non-contact machining. As a result, it is expected that the processing results can be understood without actually performing the machining.

[0031] While embodiments of this disclosure have been described in detail above, this disclosure is not limited to the individual embodiments described above. These embodiments can be added, replaced, modified, partially deleted, etc., in any way that does not depart from the spirit of the invention or from the idea and intent of this disclosure derived from the claims and their equivalents. For example, the order of operations and processes in the embodiments described above are shown as examples only and are not limited thereto. The same applies when numerical values ​​or mathematical formulas are used in the description of the embodiments described above.

[0032] The following are annotations regarding embodiments of the present disclosure. (Annotation 1) A display device (1) according to one aspect of the present disclosure includes: a simulation result acquisition unit (110) that acquires simulation results of non-contact machining elements, including the movement of at least the axis of a predetermined non-contact machining device at each block and interpolation point between blocks of a machining program; a correlation data acquisition unit (120) that acquires correlation data showing the correlation between the non-contact machining element and the state of a workpiece machined under the non-contact machining element; a display format setting unit (130) that sets the display format of the simulation results based on the correlation data; and an output unit (150) that outputs the simulation results based on the display format set by the display format setting unit (130).

[0033] (Note 2) The display format setting unit (130) of the display device (1) according to another aspect of the present disclosure sets different colorings according to the state of the workpiece indicated by the correlation data. (Note 3) The display format setting unit (130) of the display device (1) according to another aspect of the present disclosure sets gradient colors according to the state of the workpiece indicated by the correlation data. (Note 4) The display format setting unit (130) of the display device (1) according to another aspect of the present disclosure sets symbols according to the state of the workpiece indicated by the correlation data. (Note 5) The display format setting unit (130) of the display device (1) according to another aspect of the present disclosure changes the display shape of the simulation results according to the state of the workpiece indicated by the correlation data.

[0034] (Note 6) The non-contact processing device targeted by the display device (1) in other embodiments of the present disclosure is a laser cutting machine, and the state of the workpiece indicated by the correlation data acquired by the correlation data acquisition unit (120) includes any of the following: dross, presence or absence of burrs, inability to cut, density of the cut surface, temperature rise of the workpiece, and amount of reflected light of the workpiece. (Note 7) The non-contact processing device targeted by the display device (1) in other embodiments of the present disclosure is a laser welding machine, a wire electrical discharge machine, or a processing machine that melts and adds powder, and the state of the workpiece indicated by the correlation data acquired by the correlation data acquisition unit (120) includes any of the following: spatter, melt-through, size of the melted area, height and width of the molten material, temperature rise of the workpiece, and amount of reflected light of the workpiece. (Note 8) The non-contact processing device targeted by the display device (1) in other embodiments of the present disclosure is a laser processing machine, and the non-contact processing elements indicated by the correlation data acquired by the correlation data acquisition unit (120) include any of the processing speed, focal position, laser output, frequency, duty cycle, assist gas pressure, and gap amount with the workpiece.

[0035] (Note 9) A computer-readable recording medium according to one aspect of the present disclosure records a program that causes the computer to operate as: a simulation result acquisition unit (110) that acquires simulation results of non-contact machining elements, including the movement of at least the axis of a predetermined non-contact machining device at each block and interpolation point between blocks of a machining program; a correlation data acquisition unit (120) that acquires correlation data showing the correlation between the non-contact machining element and the state of a workpiece machined under the non-contact machining element; a display format setting unit (130) that sets the display format of the simulation results based on the correlation data; and an output unit (150) that outputs the simulation results based on the display format set by the display format setting unit (130).

[0036] 1 Display device 3 Control device 4 Industrial machine 5 Network 6 Fog computer 7 Cloud server 8 Sensor 9 Simulation device 11 CPU 12 ROM 13 RAM 14 Non-volatile memory 15, 17, 18, 20 Interface 22 Bus 70 Display device 71 Input device 72 External device 110 Simulation result acquisition unit 120 Correlation data acquisition unit 130 Display format setting unit 150 Output unit 210 Correlation data storage unit

Claims

1. A display device comprising: a simulation result acquisition unit that acquires simulation results of non-contact machining elements, including the movement of at least the axis of a predetermined non-contact machining device, at each block and interpolation point between blocks of a machining program; a correlation data acquisition unit that acquires correlation data showing the correlation between the non-contact machining element and the state of the workpiece machined under the non-contact machining element; a display format setting unit that sets the display format of the simulation results based on the correlation data; and an output unit that outputs the simulation results based on the display format set by the display format setting unit.

2. The display device according to claim 1, wherein the display format setting unit sets different colors according to the state of the workpiece indicated by the correlation data.

3. The display device according to claim 1, wherein the display format setting unit sets a gradient of colors according to the state of the workpiece indicated by the correlation data.

4. The display device according to claim 1, wherein the display format setting unit sets a symbol corresponding to the state of the workpiece indicated by the correlation data.

5. The display device according to claim 1, wherein the display format setting unit changes the display shape of the simulation result according to the state of the workpiece indicated by the correlation data.

6. The display device according to any one of claims 1 to 5, wherein the non-contact processing device is a laser cutting machine, and the state of the workpiece indicated by the correlation data acquired by the correlation data acquisition unit includes any of the following: presence or absence of dross and burrs, inability to cut, density of the cut surface, temperature rise of the workpiece, and amount of reflected light of the workpiece.

7. The non-contact processing device is a laser welding machine, a wire electrical discharge machine, or a processing machine that melts and adds powder, and the state of the workpiece indicated by the correlation data acquired by the correlation data acquisition unit includes any of spatter, melt-through, size of the melted area, height and width of the molten add-on, temperature rise of the workpiece, and amount of reflected light of the workpiece, as described in any one of claims 1 to 5.

8. The display device according to any one of claims 1 to 5, wherein the non-contact processing device is a laser processing machine, and the non-contact processing element indicated by the correlation data acquired by the correlation data acquisition unit includes any of the processing speed, focal position, laser output, frequency, duty cycle, assist gas pressure, and gap amount with the workpiece.

9. A computer-readable recording medium that records a program causing a computer to operate as: a simulation result acquisition unit that acquires simulation results of non-contact machining elements, including the movement of at least the axis of a predetermined non-contact machining device, in each block and interpolation points between blocks of a machining program; a correlation data acquisition unit that acquires correlation data showing the correlation between the non-contact machining element and the state of a workpiece machined under the non-contact machining element; a display format setting unit that sets the display format of the simulation results based on the correlation data; and an output unit that outputs the simulation results based on the display format set by the display format setting unit.

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