Display device and display method
Patent Information
- Authority / Receiving Office
- WO · WO
- Patent Type
- Applications
- Current Assignee / Owner
- FANUC LTD
- Filing Date
- 2025-02-03
- Publication Date
- 2026-08-06
Smart Images
Figure JP2025003354_06082026_PF_FP_ABST
Abstract
Description
Display device and display method
[0001] The present disclosure relates to a display device that displays the current machining status as a moving image of machining simulation or the like.
[0002] During machining of a machine tool, the machining status of the workpiece is often not clearly visible because coolant (cutting fluid) is applied to the workpiece or the like, or because chips (swarf) are present around the workpiece. When the machining status is not clearly visible, it is necessary to temporarily stop the machining in order to check how far the machining has progressed or whether the machining is being performed correctly.
[0003] To solve this problem, Patent Document 1 and Patent Document 2 propose a method of pre-acquiring an image inside the machine tool and displaying it in combination with a simulation image. Further, Patent Document 3 proposes an image display device that enables display of an image on a machine tool.
[0004] Japanese Patent No. 6470323, Japanese Unexamined Patent Application Publication No. 2009-266221, Japanese Unexamined Patent Application Publication No. 2018-101348
[0005] (Visual obstacle) However, the methods proposed in Patent Document 1 and Patent Document 2 are methods of displaying a pre-prepared image and a simulation image in combination. Therefore, although the above method can be a means for checking how far the machining has progressed, it cannot be a means for checking whether the machining is actually progressing correctly.
[0006] Therefore, it is assumed that even if an unexpected situation such as vibration of the feed axis or vibration of the spindle occurs and machining defects occur due to this, it may not be possible to notice the occurrence during machining.
[0007] Also, even when checking the machining status by a visual or photographed image instead of a simulation image, the machined status of the workpiece may not be clearly visible due to reasons such as coolant being applied to the workpiece, machining on a large machine tool, or machining in a deep part of the workpiece. Even in such a case, it is desirable to correctly grasp the machining status and be able to immediately stop the machining when an abnormality occurs.
[0008] (Predicting the future) Furthermore, conventional pre-processing simulations predict future processing defects by setting hypothetical processing conditions, such as tool wear or macro branching, before processing. Therefore, conventional processing simulations cannot predict future processing defects based on conditions that change during actual processing. In order to prevent abnormalities from occurring, it is important to accurately predict whether problems will occur in the future based on the current situation and to verify the operation at hand.
[0009] (Past Analysis) Furthermore, no technology has been proposed to easily check past processing conditions. When processing defects occur, it is preferable to identify the cause, take countermeasures, and then resume processing. For this purpose, it is important to be able to check simulated past processing conditions.
[0010] As described above, conventional technologies have the challenge of being unable to accurately simulate future conditions or to verify simulated past processing conditions. Therefore, this disclosure aims to provide a display device and display method that can easily verify past or future processing conditions.
[0011] The machine tool display device of this disclosure is a display device positioned on the machine tool for displaying a machining simulation to confirm the machining status of the machine tool, and comprises a machining simulation data acquisition unit that acquires a machining image or machining video generated by a machining simulation based on position information used to drive the mechanism of the machine tool, and a machining simulation display unit that displays the machining image or machining video acquired by the machining simulation data acquisition unit, wherein the machining simulation data acquisition unit acquires the results of a machining simulation using the current, past, or future position information while the machine tool is being driven, and the machining simulation display unit displays the machining image or machining video from the past or future of the present by a predetermined operation.
[0012] Furthermore, the method for displaying a machine tool is a method for displaying a machining simulation in order to check the machining status of the machine tool, and includes the steps of: acquiring current, past, or future position information used for driving; performing a machining simulation based on the position information; acquiring a machining image or machining video of the present, past, or future generated by the machining simulation; and displaying the acquired machining image or machining video of the present, past, or future.
[0013] The display device and display method of this disclosure provide a display device and display method that allow for easy confirmation of past or future processing status.
[0014] This is a front view of a machine tool illustrating an overview of a machining simulation display device according to an embodiment of the present disclosure. This is a front view of a conventional machine tool equipped with a window. This is a block diagram illustrating an overview of a machining simulation display device according to the first embodiment of the present disclosure. This is a front view of a machine tool illustrating an overview of a machining simulation display device according to Example 1 of the present disclosure. This is a block diagram illustrating an overview of a machining simulation display device according to the second embodiment of the present disclosure. This is a block diagram illustrating an overview of a machining simulation display device according to the third embodiment of the present disclosure. This is a block diagram illustrating an overview of a machining simulation display device according to the fourth embodiment of the present disclosure. This is a block diagram illustrating an overview of a machining simulation display device according to the fifth embodiment of the present disclosure. This is a block diagram illustrating an overview of a machining simulation display device according to the sixth embodiment of the present disclosure. This is a flowchart showing the processing flow of the display method of the present disclosure.
[0015] (First Embodiment) The machining simulation display device 1 of the first embodiment of the present disclosure will be described with reference to Figures 1A and 2, etc. The machining simulation display device 1 is one embodiment of the display device of the present disclosure.
[0016] (Machine tool and machining simulation display device) Figure 1A is a front view of the machine tool 100 of this embodiment, showing an overview of the machine tool 100 in which the machining simulation display device 1 is located. Figure 1B is a front view of the machine tool 1001, showing an overview of a conventional machine tool 1001 equipped with a window 200. The machine tool is, for example, a machine tool used to machine molds.
[0017] (Overview of the Machining Simulation Display Device) As shown in Figure 1A, the machine tool 100 of this embodiment is equipped with a machining simulation display device 1. The machining simulation display unit 34 of the machining simulation display device 1 displays machining images or machining videos that show the past or future machining status of a workpiece generated by the machining simulation. The operator of the machine tool 100 can check the past or future status of machining of the workpiece by looking at the machining images or machining videos displayed on the machining simulation display unit 34. In addition to the past or future, the machining simulation display unit 34 may also display machining images or machining videos that show the current status of machining of the workpiece.
[0018] As shown in Figure 1B, a conventional machine tool 1001 is equipped with a window 200. The operator of the machine tool 1001 checks the current status of the workpiece through the window 200. The operator checks the actual workpiece. Therefore, the operator cannot check the past or future status of the workpiece.
[0019] In contrast, the operator of the machine tool 100 in this embodiment can check the past or future status of the workpiece by the display on the machining simulation display unit 34.
[0020] Furthermore, operators may find it difficult to check the current status of a workpiece due to factors such as the presence of coolant or the position of the workpiece. In this embodiment, the operator of the machine tool 100 can check the current status of the workpiece through the display on the machining simulation display unit 34. Therefore, the current status of the workpiece can be easily checked.
[0021] Furthermore, the callout 1000 in Figure 1A shows an example where an enlarged and modified image is displayed on the machining simulation display unit 34. The image displayed on the machining simulation display unit 34 can be an enlarged image of the area the operator wants to see, or an image from the operator's desired viewpoint. This allows the operator to more easily check the status of the workpiece being machined.
[0022] Furthermore, the image displayed on the machining simulation display unit 34 can be rewound to the past and fast-forwarded to the future. This will be explained in detail below.
[0023] (Configuration of the Machining Simulation Display Device) Figure 2 is a block diagram showing an overview of the machining simulation display device 1 according to the first embodiment of the present disclosure. As shown in Figure 2, the machining simulation display device 1 includes a machining simulation data acquisition unit 32 and a machining simulation display unit 34. The machining simulation data acquisition unit 32 is the part that acquires machining images or machining videos generated by the machining simulation. The machining simulation display unit 34 is the part that displays the machining images or machining videos acquired by the machining simulation data acquisition unit 32.
[0024] This section explains the overall flow of the machining simulation. Note that the following explanation is illustrative, and the placement of each functional component in the device can be modified as needed.
[0025] (Control device) In the example shown in Figure 2, the machine tool 100 is equipped with a control device 110. The control device 110 is a device that controls each part of the machine tool 100. The control device 110 may be equipped with a display unit for displaying information, an input unit for inputting control content, and so on.
[0026] (Control Processing Unit) The control device 110 includes a control processing unit 120. The control processing unit 120 is the part of the control device 110 that processes data used for control. The control processing unit 120 holds position information for each axis during machining.
[0027] (Simulator device) The simulator device 10 is a device that performs machining simulations. The simulator device 10 includes a machining simulation processing unit 12. The machining simulation is performed in the machining simulation processing unit 12.
[0028] Functionally, the control device 110 of the machine tool 100, the simulator device 10, and the machining simulation display device 1 are connected in this order. However, the physical positions of the control device 110 of the machine tool 100, the simulator device 10, and the machining simulation display device 1 can be changed as appropriate. For example, unlike the configuration illustrated in Figure 2, the simulator device 10 may be located on the machine tool 100.
[0029] In particular, there are no specific limitations on where the simulator device 10 and the machining simulation processing unit 12 are located. In the example shown in Figure 2, the simulator device 10 is located as a separate device from the control device 110 and the machining simulation display device 1. The machining simulation processing unit 12 is located within the simulator device 10.
[0030] Unlike the example shown in Figure 2, the simulator device 10 may be located on the control device 110. Alternatively, the simulator device 10 may be located on the machining simulation display device 1.
[0031] Alternatively, instead of providing the simulator device 10 as a separate and independent part from the control device 110 and the machining simulation display device 1, the control device 110 or the machining simulation display device 1 may perform the machining simulation.
[0032] (Process Flow) The process flow, including machining simulation, will be explained. Refer to Figure 9 in the following explanation. Figure 9 is a flowchart showing the process flow of the machine tool display method of this disclosure. In the following explanation and in Figure 9, S1 indicates step 1, and S2 indicates step 2. The same applies to S3 and subsequent steps. The process starts from S1 and ends at S4.
[0033] (S1) S1 is a location information acquisition step. In S1, current, past, or future location information to be used for driving is acquired.
[0034] Specifically, the machining simulation processing unit 12 acquires position information from the control processing unit 120. This position information is the position information used for the current drive when the mechanical parts of the machine tool 100 are driven.
[0035] The location information currently used for driving becomes past location information as it is accumulated. In other words, past location information can be obtained by reading it from the accumulated location information. This will be explained later.
[0036] Furthermore, past location information can be retrieved retrospectively by analyzing the processing program.
[0037] Furthermore, future location information can be obtained, for example, by predicting and analyzing the processing program.
[0038] In S1, machining conditions may be acquired in addition to position information. Machining conditions refer to the various conditions in machining by a machine tool. Specific examples of machining conditions include tool wear and macro variables in the machining program. Macro variables include all the numerical values and conditions required during machining. Macro variables may include, for example, tool correction values and machining dimensions.
[0039] Current processing conditions, like location information, are accumulated and become past processing conditions. In other words, past processing conditions can be retrieved by reading from the accumulated processing conditions.
[0040] Furthermore, future processing conditions can be predicted based on current processing conditions, taking into account the processing content from the present to the future.
[0041] (S2) S2 is a machining simulation step. In S2, a machining simulation is performed based on the position information obtained in S1. In addition, in S2, the machining simulation can also be performed by considering machining conditions in addition to position information.
[0042] Specifically, the machining simulation processing unit 12 performs machining simulation. In the machining simulation, a machining image or a machining video is generated based on the position information used for the current drive.
[0043] That is, the machining image and the machining video are, respectively, an image generated by simulation (simulation image) and a video generated by simulation (simulation video). Note that the machining image or the machining video may be described as "machining image etc.".
[0044] Also, the machining image etc. may be generated in real time. By generating the machining image etc. in real time, the current machining status can be displayed without delay.
[0045] Also, machining simulation can be performed based on past position information and past machining conditions. By performing machining simulation based on past position information and past machining conditions, a machining image etc. indicating the past machining status can be obtained.
[0046] Note that the machining image etc. indicating the past machining status can be obtained from the accumulated machining image etc. by accumulating the machining image etc. indicating the current machining status. This will be described later.
[0047] Also, machining simulation can be performed based on future position information and future machining conditions. By performing machining simulation based on future position information and future machining conditions, a machining image etc. indicating the future machining status can be obtained.
[0048] Note that the types of position information (program command position, position command, position feedback value, position feedback estimated value, etc.) and the content of each position information will be described later.
[0049] (S3) S3 is a machining image etc. acquisition step. In S3, the machining image or the machining video generated in S2 is acquired.
[0050] Specifically, the processing simulation data acquisition unit 32 acquires simulation results, such as current or future processed images or processed videos, from the processing simulation processing unit 12. The processing simulation data acquisition unit 32 may also acquire past processed images, etc.
[0051] (S4) S4 is the processed image display step. In S4, the processed image or processed video acquired in S3 is displayed.
[0052] Specifically, the machining simulation display unit 34 acquires machining images or machining videos from the machining simulation processing unit 12 and displays them. By displaying the machining images, etc., on the machining simulation display unit 34, the operator of the machine tool 100 can check the current, past, or future machining status by looking at the display on the machining simulation display unit 34.
[0053] The processing flow ends at S4.
[0054] As described above, in the machining simulation display device 1, the machining simulation data acquisition unit 32 acquires the results of a machining simulation using the current, past, or future position information of the machine tool 100 while it is in operation, and the machining simulation display unit 34 displays a machining image or machining video from the past or future of the present through a predetermined operation. Alternatively, the machining simulation display unit 34 may also display the current machining image or machining video through a predetermined operation.
[0055] An embodiment of the machining simulation display device 1 of this embodiment will be described with reference to the drawings. The following description of the embodiment will explain the differences from the machining simulation display device 1 shown in Figure 1A.
[0056] (Example 1) Example 1 will be described with reference to Figure 3. Figure 3 is a front view of a machine tool 100 showing an overview of the machining simulation display device 1 of Example 1. In Example 1 shown in Figure 3, unlike the machine tool 100 shown in Figure 1A, the machine tool 100 is equipped with a window 200 in addition to the machining simulation display device 1.
[0057] In the machine tool 100 of Embodiment 1, the operator 500 can process a mold in the machine tool 100, which is equipped with both a window 200 and a machining simulation display device 1. Therefore, the operator 500 can observe the inside of the machine tool 100 in two ways: by viewing the display on the machining simulation display unit 34 as shown by arrow 510, and by viewing the inside of the machine tool 100 through the window 200 as shown by arrow 520.
[0058] Normally, during machining, coolant and chips are scattered inside the machine tool 100, so the operator 500 cannot see the machining process through the window 200. However, in the machine tool 100 of Embodiment 1, a machining simulation display device 1 is installed. Therefore, the operator 500 can see the machining process through the display of the machining simulation display unit 34 of the machining simulation display device 1.
[0059] Furthermore, when simulating using position feedback values, which will be explained later, it is possible to check whether any processing defects, such as stripes, have occurred on the processed surface, even during processing. This is because processed images or videos simulated using position feedback values can easily show a situation closer to the actual processing conditions. Note that position feedback values include both position feedback values and position feedback estimates, which will be explained later.
[0060] Furthermore, the processing simulation display device 1 can display processing images and other data retrospectively, from the present to the past.
[0061] Therefore, if a processing defect occurs, the display time is rewound and the processed image is displayed. Let's say that unexpected vibrations occurred in the previously displayed processed image. In this case, the processing is first stopped.
[0062] For example, if it is determined from saved past simulation videos (processed images) that the cause of a processing defect was that the fast-forwarding was too fast just before the defect occurred, the processing parameters are corrected and the next processing is performed. This allows subsequent processing to be performed normally without any processing defects.
[0063] In this way, the machining simulation display device 1 can reduce unnecessary machining caused by machining defects and other issues. It can also efficiently identify the causes of machining defects. The saving of machining images will be explained in detail later.
[0064] Furthermore, in Embodiment 1, a window 200 is provided in addition to the machining simulation display device 1. Therefore, when machining is stopped or when coolant is not splashing, the machining simulation display device 1 can be turned off, and the inside of the machine tool 100 can be checked through the window 200.
[0065] Furthermore, in Example 1, a window 200 is provided in addition to the machining simulation display device 1. Therefore, even if it is difficult to check the machining status in detail through the window 200 due to coolant or other factors during machining, the window 200 can serve as one factor in determining whether the display on the machining simulation display unit 34 is clearly correct. As a result, if an error occurs in the machining simulation display device 1 due to any factor, it becomes possible to identify that error early.
[0066] (Example 2) Another embodiment of the machining simulation display device 1 will be described. For example, suppose that in a general machining simulation performed in advance, no machining defects occurred and there seemed to be no problems with the machining, so the actual machining was performed.
[0067] Suppose that after starting the actual machining process, measurements taken during the machining cycle revealed that the degree of tool wear was different from what was expected.
[0068] In this case, based on the measurement results, the future processing status is predicted through processing simulation. Suppose that when the prediction results are viewed on the processing simulation display device 1, it is found that processing defects that were not seen in the prior simulation will occur. Based on these simulation results, the operator can interrupt the processing. This prevents the occurrence of processing defects.
[0069] (Example 3) Another embodiment of the machining simulation display device 1 will be described. Similar to Example 2, a general machining simulation performed in advance showed no machining defects and no apparent problems with the machining process, so the actual machining was performed.
[0070] Suppose that after actual machining has started, macro variables are manipulated by an external communication device, causing machining parameters and other settings to deviate from expected values. The future machining situation is predicted using machining simulation. When the prediction results are viewed on the machining simulation display device 1, it is found that the branching of the machining program has changed due to these macro variables, resulting in axis movement different from what was initially expected. Based on these simulation results, the operator can interrupt the machining process. This prevents the occurrence of machining defects.
[0071] (Position Information) The position information used in the machining simulation will be explained below. The position information can be any one of the following: the program command position obtained by the control device 110 analyzing the machining program; the position command output by the control device 110 to the servo control unit of each axis after performing acceleration / deceleration and smoothing processing on the program command position; the position feedback value obtained by the servo control unit of each axis from the position detector to control the position of each axis; or the position feedback estimate value obtained by inputting the position command into the servo model generated by analyzing the position control characteristics of each axis. These will be explained in order below.
[0072] (Program command position, position command) The case where the position information is a program command position or a position command will be explained. As shown in Figure 2, the position information is input to the simulator device 10. This position information is the position information used by the control processing unit 120 of the control device 110 to control the current drive of each mechanism.
[0073] The program command position or position command can be used as position information. (Program command position) First, let's explain the case where the program command position is used as position information. The program command position is the command position for each mechanism described in the machining program. A mechanism refers to, for example, a shaft. The mechanism is not shown in Figure 2, but it is shown in Figure 4. The program command position can be obtained, for example, by the control device 110 analyzing the machining program.
[0074] (Position Command) Next, we will explain the case where position commands are used as position information. A position command is a command regarding the axis position, etc., that is input to the servo control unit of each axis. The servo control unit is not shown in Figure 2, but is shown in Figure 4. The servo control unit can be provided for each axis, for example, within the mechanism unit 122.
[0075] The position command is generated by the control device 110 performing acceleration / deceleration and smoothing processing on the programmed command position. The position command is output from the control device 110 to the servo control unit of each axis.
[0076] The machining simulation processing unit 12 of the simulator device 10 can perform machining simulations (machining simulation processing) based on the program command position or position command as input position information, and generate simulation results in real time. In addition to the program command position or position command, the machining simulation processing unit 12 can also perform machining simulations based on machining conditions.
[0077] The same approach can be applied to future location information. Future location information can be obtained by predicting and analyzing the processing program to acquire future program command positions. Furthermore, future location commands can be acquired based on the acquired future program command positions.
[0078] Furthermore, past location data can be converted to past location data by accumulating current location data.
[0079] As mentioned above, the simulator device 10 can be any device. The simulator device 10 can be placed in any location, such as inside the control device 110, inside the machining simulation display device 1, or outside the control device 110 and the machining simulation display device 1.
[0080] The machining simulation data acquisition unit 32 located within the machining simulation display device 1 acquires the generated machining simulation results from the machining simulation processing unit 12. The machining simulation data acquisition unit 32 acquires the machining simulation results from the machining simulation processing unit 12, for example, via communication or shared memory.
[0081] The machining simulation display unit 34 within the machining simulation display device 1 displays the machining simulation acquired by the machining simulation data acquisition unit 32. This allows the operator to check the current machining status of the workpiece.
[0082] (Second Embodiment) A second embodiment will be described in which the position information is a position feedback value. Figure 4 is a block diagram showing an overview of the machining simulation display device 1 of the second embodiment of this disclosure. The second embodiment will be described focusing on the differences from the first embodiment. Matters not specifically described in the second embodiment can be the same as in the first embodiment.
[0083] As shown in Figure 4, in the second embodiment, unlike the first embodiment shown in Figure 2, the control device 110 of the machine tool 100 includes a mechanism 122 and a position detector 124 in addition to the control processing unit 120. The mechanism 122 includes, for example, the axis of the machine tool 100. The position detector 124 is a device that detects the position of the mechanism 122.
[0084] Furthermore, the mechanism unit 122 includes a servo control unit 126. The servo control unit 126 is the part that drives the shafts of the mechanism unit 122 in response to position commands or movement commands from the control processing unit 120 or the like.
[0085] In the second embodiment, position feedback values are used as position information in the machining simulation process. Position feedback values are defined as values indicating the position of each mechanism, which are obtained based on measurement results from detectors, sensors, etc.
[0086] When the control processing unit 120 of the control device 110 controls the current drive of each mechanism 122, each mechanism 122 is driven as a result. In the example shown in Figure 4, the control processing unit 120 sends a movement command to the mechanism 122, causing the mechanism 122 to be driven.
[0087] (Position Detector) The position of each mechanism 122 after this drive is detected by, for example, a position detector 124. Then, the information regarding the detected position, i.e., the position feedback value, is used as position information.
[0088] The machining simulation processing unit 12 acquires position feedback values as position information from the mechanism unit 122 and performs machining simulation processing. The machining simulation processing unit 12 can generate simulation results based on the position feedback values in real time. Processing after the machining simulation can be done in the same manner as in the first embodiment.
[0089] Furthermore, the current location information can be stored and converted into past location information. In other words, the location feedback value can be used as location information to simulate past processing conditions.
[0090] In the second embodiment, the actual position detected by a position detector or the like is used as position information, and the machining simulation is performed based on that position information. Therefore, even if the axis does not move according to the movement command, a machining simulation that is closer to the actual machining situation can be performed.
[0091] (Third Embodiment) A third embodiment will be described in which the position information is a position feedback estimate. Figure 5 is a block diagram showing an overview of the machining simulation display device 1 of the third embodiment of this disclosure. The third embodiment will be described focusing on the differences from the first embodiment. Matters not specifically described in the third embodiment can be the same as in the first embodiment.
[0092] (Servo Model) As shown in Figure 5, in the third embodiment, unlike the first embodiment shown in Figure 2, the simulator device 10 includes a servo model processing unit 14 in addition to the machining simulation processing unit 12. The servo model processing unit 14 stores the servo model and performs processing using the servo model. The servo model is a model generated by analyzing the position control characteristics of each axis. The servo model outputs an estimated position value based on the input movement command. The estimated position value output by the servo model is defined as the position feedback estimate.
[0093] In the third embodiment, the control processing unit 120 of the control device 110 inputs movement commands used to control the current drive of each mechanism to an arbitrary simulator device 10. Specifically, the movement commands are input from the control processing unit 120 of the control device 110 to the servo model processing unit 14 of the simulator device 10.
[0094] In the servo model processing unit 14, servo model processing is performed in response to the input movement command. Specifically, the movement command is input to the stored servo model in the servo model processing unit 14. The servo model outputs an estimated position value based on the input movement command. This estimated position value is the position feedback estimate.
[0095] The machining simulation processing unit 12 acquires position feedback estimates as position information and performs machining simulation processing. The machining simulation processing unit 12 generates simulation results based on the position feedback estimates in real time. Processing after the machining simulation can be done in the same manner as in the first embodiment.
[0096] Similarly, estimated position feedback values can be obtained for future positional information. By predicting and analyzing the machining program, future program command positions are obtained, and then position commands are acquired. By inputting these command positions into the servo model, estimated future position feedback values can be obtained.
[0097] Furthermore, current location information can be stored and converted into past location information. In other words, by using location feedback estimates as location information, it is possible to simulate past processing conditions.
[0098] In the third embodiment, the machining simulation is performed using position feedback estimates output by a servo model generated by analyzing the axis position control characteristics as position information. Therefore, machining simulations that are closer to actual machining conditions can be performed without adding equipment that actually measures position, such as position detectors.
[0099] (Fourth Embodiment) The fourth embodiment of this embodiment will be described with reference to Figure 6. Figure 6 is a block diagram showing an overview of the processing simulation display device 1 of the fourth embodiment of this disclosure. The fourth embodiment will be described focusing on the differences from the first embodiment. Matters not specifically described in the fourth embodiment can be the same as in the first embodiment.
[0100] In the processing simulation display device 1 of this embodiment, the processing simulation data acquisition unit 32 can acquire processing images or processing videos from the past by saving the processing images or processing videos generated using the current location information.
[0101] Unlike the machining simulation display device 1 of the first embodiment, the machining simulation display device 1 of this embodiment further includes a machining simulation data storage area 40. The machining simulation data storage area 40 is an area for storing the machining simulation results generated by the machining simulation processing unit 12. The machining simulation data storage area 40 can be configured by, for example, a memory device.
[0102] The processing flow in this embodiment will be described in order. The control processing unit 120 of the control device 110 inputs the position information used to control the current drive of each mechanism 122 to an arbitrary simulator device 10. The mechanism 122 is not shown in Figure 6, but is shown in Figure 4. Furthermore, "arbitrary simulator device 10" means that the area in which the simulator device 10 is located is not particularly limited. The simulator device 10 can be placed in any location, such as inside the control device 110, inside the machining simulation display device 1, or outside of these locations.
[0103] The simulator device 10 performs machining simulation processing and generates simulation results in real time. The machining simulation processing is performed by the machining simulation processing unit 12 of the simulator device 10.
[0104] The machining simulation data acquisition unit 32, located within the machining simulation display device 1, acquires the generated machining simulation results via communication or through shared memory, etc. In particular, the machining simulation data acquisition unit 32 acquires the generated current or future simulation results.
[0105] The machining simulation data acquisition unit 32 stores the acquired machining simulation data in the machining simulation data storage area 40. The stored machining simulation data is then used to represent the machining status at a certain point in the past. In other words, the current machining status is stored as a machining status from a past point in time.
[0106] The machining simulation display unit 34 located within the machining simulation display device 1 reads the machining simulation results stored in the machining simulation data storage area 40 and displays the read machining simulation results as past machining status.
[0107] In this way, the machining simulation display device 1 of this embodiment allows the operator to check the past machining status of the workpiece.
[0108] In this embodiment, the machining simulation display device 1 displays the past machining status of a workpiece by reading machining images and the like that were generated and saved to display the current machining status. Therefore, the machining simulation display device 1 in this embodiment does not need to generate new past machining status of the workpiece each time it is displayed. As a result, the past machining status of the workpiece can be easily displayed.
[0109] (Fifth Embodiment) The fifth embodiment of this embodiment will be described with reference to Figure 7. Figure 7 is a block diagram showing an overview of the processing simulation display device 1 of the fifth embodiment of this disclosure. The fifth embodiment will be described focusing on the differences from the fourth embodiment. Matters not specifically described in the fifth embodiment can be the same as in the fourth embodiment.
[0110] In the processing simulation display device 1 of this embodiment, the processing simulation data acquisition unit 32 stores location information to obtain location information from the past, and by acquiring the results of a processing simulation using past location information, it can acquire processed images or processed videos from the past.
[0111] Unlike the machining simulation display device 1 of the fourth embodiment shown in Figure 6, the machining simulation display device 1 of this embodiment does not have a machining simulation data storage area 40. In the machining simulation display device 1 of this embodiment, the simulator device 10, which is an arbitrary device, further includes a position information data storage area 42 in addition to the machining simulation processing unit 12.
[0112] The location information data storage area 42 is an area in the control processing unit 120 that stores location information. The control processing unit 120 stores the location information in the location information data storage area 42. The location information data storage area 42 can be configured by, for example, a memory device.
[0113] The processing flow in this embodiment will be described in order. The control processing unit 120 of the control device 110 stores the position information used to control the driving of each mechanism 122 in the position information data storage area 42 of any simulator device 10. The mechanism 122 is not shown in Figure 7, but is shown in Figure 4.
[0114] The simulator device 10 performs machining simulation processing to generate simulation results. Specifically, the machining simulation processing unit 12 of the simulator device 10 reads and acquires the position information stored in the position information data storage area 42. The machining simulation processing unit 12 uses the acquired position information as position information from the past rather than the present to perform the machining simulation.
[0115] In other words, the simulator device 10 stores location information and uses that stored location information as location information at a certain point in the past. Then, it uses this location information to perform a machining simulation process and generate past simulation results.
[0116] The machining simulation data acquisition unit 32 located within the machining simulation display device 1 acquires the generated past machining simulation results from the machining simulation processing unit 12 via communication or shared memory.
[0117] The machining simulation display unit 34 within the machining simulation display device 1 displays past machining simulation results acquired by the machining simulation data acquisition unit 32. This allows the operator to check the past machining status of the workpiece.
[0118] In this embodiment, the machining simulation display device 1 generates machining simulation results showing past machining conditions using stored position information. Therefore, past machining simulations are generated only as needed. As a result, the machining simulation display device 1 of this embodiment can reduce the burden on the device's data processing.
[0119] (Sixth Embodiment) The sixth embodiment of this embodiment will be described with reference to Figure 8. Figure 8 is a block diagram showing an overview of the processing simulation display device 1 of the sixth embodiment of this disclosure. The sixth embodiment will be described focusing on the differences from the first embodiment. Matters not specifically described in the sixth embodiment can be the same as in the first embodiment.
[0120] In the machining simulation display device 1 of this embodiment, the control processing unit 120 generates program command positions by looking up the machining program, and uses this as future position information for the position commands. The machining simulation data acquisition unit 32 then acquires machining images or machining videos from the future by acquiring the results of the machining simulation using the future position information.
[0121] Furthermore, in the machining simulation display device 1 of this embodiment, the machining simulation data acquisition unit 32 can acquire simulation results that take into account not only position information but also current machining conditions including tool wear and macro variables. Based on these simulation results, it is possible to generate machining images or machining videos that represent the future rather than the present.
[0122] In this embodiment of the machining simulation display device 1, unlike the machining simulation display device 1 of the first embodiment, the control processing unit 120 of the control device 110 inputs a pre-read machining program, rather than position information, to the machining simulation processing unit 12 of any simulator device 10.
[0123] Furthermore, the control processing unit 120 inputs machining conditions such as current tool wear and macro variables, in addition to the pre-read machining program, to the machining simulation processing unit 12.
[0124] Next, the simulator device takes the current machining conditions into account and uses a pre-calculated machining program to perform a machining simulation process and generate predicted future simulation results.
[0125] Furthermore, the processing conditions may be based on the current processing conditions, but may also be future processing conditions predicted by considering a pre-calculated processing program.
[0126] The machining simulation data acquisition unit 32 located within the machining simulation display device 1 acquires the generated future machining simulation results from the machining simulation processing unit 12 via communication or shared memory.
[0127] Next, the machining simulation display unit 34 within the machining simulation display device 1 displays the future machining simulation results acquired by the machining simulation data acquisition unit 32. This allows the operator to check the future machining status of the workpiece.
[0128] The embodiments of this disclosure have been described above. This disclosure is not limited to the embodiments described above, and various modifications, variations, and combinations are possible.
[0129] For example, the machining simulation display device 1 may simultaneously display two or more machining images or videos from the present, past, or future, through a predetermined operation. This makes it easy to eliminate the windows that were conventionally provided in machine tools.
[0130] (Summary) This disclosure simulates and displays the operation of a machine tool and the machining process based on the position information of each axis acquired from the machine tool's control device during machining. It also saves past simulation results, allowing users to rewind to past instances where machining defects occurred as needed. Furthermore, by predicting and displaying future simulation results, it is possible to check the machining status at future times while taking actual machining conditions into account.
[0131] (Solution) This disclosure provides a new processing simulation display device, which is a display device for displaying processing simulations. It also provides a new processing simulation data acquisition unit that acquires processing images or processing videos generated by processing simulations performed based on position information. Furthermore, it provides a new processing simulation display unit that displays the acquired video images and allows users to check the processing status.
[0132] The machining simulation data acquisition unit acquires machining images or machining videos generated as a result of a simulation performed based on position information used to drive the machine tool. The machining simulation display unit displays the generated machining video or machining image.
[0133] With the configuration described above, the machining simulation display device of this disclosure allows, for example, if a scratch is found on the machined surface of a workpiece, to rewind the displayed time even during machining to identify the moment the scratch occurred. Furthermore, it allows for understanding the circumstances under which machining defects such as scratches occurred.
[0134] Furthermore, by rewinding the simulation display to the point where a machining defect occurred, the operator can assess the situation of the defect. Therefore, the operator can interrupt the machining process only when a defect occurs, and immediately resume the next machining process after corrective action is taken.
[0135] By using simulation displays to predict machining conditions at future times, operators can interrupt machining and take corrective action before machining defects occur if the conditions remain unchanged. This reduces wasted machining and improves work efficiency.
[0136] Furthermore, by reducing the amount of processed workpieces that are wasted, the environmental impact can be minimized. In addition, energy consumption can be reduced.
[0137] Furthermore, by simultaneously displaying the current simulation and past or future simulations, it is possible to monitor the current machining status during processing while checking past or future machining status in order to obtain the aforementioned effects related to the past or future.
[0138] The following additional information is disclosed regarding the above embodiments and modifications.
[0139] (Note 1) A display device (1) positioned on a machine tool (100) for displaying a machining simulation to check the machining status of the machine tool (100), comprising: a machining simulation data acquisition unit (32) that acquires a machining image or machining video generated by a machining simulation based on position information used to drive the mechanism (122) of the machine tool (100); and a machining simulation display unit (34) that displays the machining image or machining video acquired by the machining simulation data acquisition unit (32), wherein the machining simulation data acquisition unit (32) acquires the results of a machining simulation using the current, past, or future position information while the machine tool (100) is being driven, and the machining simulation display unit (34) displays the machining image or machining video from the past or future of the present by a predetermined operation.
[0140] (Note 2) The machine tool (100) is equipped with a control device (110), and the position information is a display device (1) which includes one of the following: a program command position in the program obtained by the control device (110) analyzing the machining program; a position command output by the control device (110) to the servo control unit (126) of each axis after performing acceleration / deceleration and smoothing processing on the program command position; position feedback obtained by the servo control unit (126) of each axis from a position detector (124) in order to control the position of each axis; or a position feedback estimate obtained by inputting the position command into a servo model generated by analyzing the position control characteristics of each axis.
[0141] (Note 3) The processing simulation data acquisition unit (32) is a display device (1) that acquires the processing image or processing video from the past by saving the processing image or processing video generated using the current position information.
[0142] (Note 4) The processing simulation data acquisition unit (32) stores the position information to obtain the position information from the past, and the display device (1) acquires the processed image or processed video from the past by acquiring the results of a processing simulation using the past position information.
[0143] (Note 5) The processing simulation data acquisition unit (32) generates program command positions by looking up the processing program, uses the future position information for the position commands, and acquires the processing image or processing video from the future by acquiring the results of the processing simulation using the future position information.
[0144] (Note 6) The display device (1) is a display device (1) that simultaneously displays two or more of the processed images or processed videos from the present, the past, or the future by the predetermined operation.
[0145] (Note 7) The processing simulation data acquisition unit (34) acquires simulation results that take into account the current processing conditions, including tool wear and at least one of macro variables, in addition to the position information, and a display device (1) that generates the processing image or processing video from the present to the future.
[0146] (Note 8) A display method for displaying a machining simulation to check the machining status of a machine tool (100), comprising: a step of acquiring current, past, or future position information used for driving; a step of performing a machining simulation based on the position information; a step of acquiring a machining image or machining video of the present, past, or future generated by the machining simulation; and a step of displaying the acquired machining image or machining video of the present, past, or future.
[0147] 1 Machining simulation display device 10 Simulator device 12 Machining simulation processing unit 14 Servo model processing unit 32 Machining simulation data acquisition unit 34 Machining simulation display unit 40 Machining simulation data storage area 42 Position information data storage area 100 Machine tool 110 Control device 120 Control processing unit 122 Mechanism unit 124 Position detector 126 Servo control unit 200 Window 500 Operator 1001 Machine tool
Claims
1. A display device positioned on a machine tool for displaying a machining simulation to check the machining status of the machine tool, comprising: a machining simulation data acquisition unit that acquires a machining image or machining video generated by a machining simulation based on position information used to drive the mechanism of the machine tool; and a machining simulation display unit that displays the machining image or machining video acquired by the machining simulation data acquisition unit, wherein the machining simulation data acquisition unit acquires the results of a machining simulation using the current, past, or future position information while the machine tool is being driven, and the machining simulation display unit displays the machining image or machining video from the past or future of the present by a predetermined operation.
2. The display device according to claim 1, wherein the machine tool is equipped with a control device, and the position information includes one of the following: a program command position in a program obtained by the control device analyzing a machining program; a position command output by the control device to the servo control unit of each axis after performing acceleration / deceleration and smoothing processing on the program command position; position feedback obtained by the servo control unit of each axis from a position detector in order to control the position of each axis; and a position feedback estimate obtained by inputting the position command into a servo model generated by analyzing the position control characteristics of each axis.
3. The display device according to claim 1, wherein the processing simulation data acquisition unit acquires the processing image or processing video from a past time by storing the processing image or processing video generated using the current position information.
4. The display device according to claim 1, wherein the processing simulation data acquisition unit stores the position information to obtain the position information from the past, and acquires the processing image or processing video from the past by acquiring the results of a processing simulation using the past position information.
5. The display device according to claim 1, wherein the processing simulation data acquisition unit generates program command positions by looking up the processing program, uses the future position information for the position commands, and acquires the processing image or processing video from the future by acquiring the results of a processing simulation using the future position information.
6. The display device according to claim 1, which simultaneously displays two or more of the processed images or processed videos from the present, past, or future by the predetermined operation.
7. The display device according to claim 1, wherein the processing simulation data acquisition unit acquires simulation results that take into account the current processing conditions, including tool wear and at least one of macro variables, in addition to the position information, and generates the processing image or processing video of the present or future.
8. A display method for displaying a machining simulation to check the machining status of a machine tool, comprising the steps of: acquiring current, past, or future position information used for driving; performing a machining simulation based on the position information; acquiring a machining image or machining video of the present, past, or future generated by the machining simulation; and displaying the acquired machining image or machining video of the present, past, or future.