JP6884932B1 - Machine Tools - Google Patents

Abstract

PROBLEM TO BE SOLVED: To secure the contrast of a captured image regardless of the tool length and to detect the shape of a tool with sufficient accuracy. A machine tool opens and closes an accommodation chamber 10 in which a plurality of tools are accommodated, a processing chamber in which machining by tools is executed, and an opening 28 provided in a partition wall between the accommodation chamber 10 and the processing chamber. The shutter 30, the tool support portion 22 that supports the tool Tx to be replaced in the accommodation chamber 10, the imaging unit 50 arranged in the accommodation chamber 10, and the tool Tx fixed to the shutter 30 and supported by the tool support portion 22. 52 is provided, and an opening / closing mechanism 32 for moving the shutter 30 in the longitudinal direction of the tool Tx to open / close the opening 28. The machine tool moves the lighting unit 52 integrally with the shutter 30 to take an image of the tool Tx. [Selection diagram] Fig. 3

Description

The present invention relates to a tool inspection technique in a machine tool.

Machine tools include a turning center that moves a tool with respect to a rotating work, a machining center that moves a rotating tool with respect to a work, and a multi-tasking machine having these functions in combination. The machine tool is equipped with a tool changing device called an ATC (Automatic Tool Changer), and the work is machined into a desired shape while exchanging a plurality of types of tools in the machining process. The ATC executes tool exchange between the tool accommodating portion (magazine or the like) and the tool holding portion (spindle or the like).

In such a machine tool, if the used tool has an abnormality such as a chip, breakage, or wrapping of chips, the tool (hereinafter, also referred to as "defective tool") cannot be used as it is for the next machining. Therefore, a technique has been proposed in which the blade shape is imaged by a camera before and after the use of the tool, and whether or not the tool is defective is determined based on the captured images before and after the use of the tool (Patent Document 1).

In the tool inspection, for example, lighting is applied from one side of the tool, and the tool is imaged by a camera installed on the other side. The silhouette of the tool is projected by using the transmitted lighting, and the contour of the tool is specified based on the silhouette. If a normal contour shape cannot be obtained, it can be determined that the tool is defective.

Japanese Unexamined Patent Publication No. 2015-131357

The accuracy of such tool inspection depends on the contrast of the captured image. It is necessary to obtain a good silhouette of the tool, and for this purpose, the image target portion of the tool (for example, from the cutting edge to the cutting edge) must be uniformly illuminated. However, since the dimensions of the tools accommodated in the tool accommodating portion vary, if the tools are too large for the illumination range, uniform illumination becomes difficult. On the other hand, it is disadvantageous in terms of cost to adopt a large lighting device in accordance with a large tool.

One aspect of the present invention is a machine tool. This machine tool has a storage chamber for accommodating a plurality of tools, a processing chamber for performing machining by tools, a shutter for opening and closing an opening provided in a partition wall between the storage chamber and the processing chamber, and a storage chamber. The tool support part that supports the tool to be replaced, the image pickup part arranged in the accommodation chamber, the lighting part that is fixed to the shutter and illuminates the tool supported by the tool support part, and the shutter is moved in the longitudinal direction of the tool. It is equipped with an opening / closing mechanism for opening / closing the opening. The machine tool moves the lighting unit integrally with the shutter to take an image of the tool.

According to the present invention, the contrast of the captured image can be ensured regardless of the tool length, and the shape of the tool can be detected with sufficient accuracy.

It is a perspective view which shows the appearance of the machine tool which concerns on embodiment. It is a side view which shows the internal structure of the tool accommodating device. It is a perspective view which shows typically the structure of a containment chamber. It is a front view which shows typically the periphery of the boundary part between a containment chamber and a processing chamber. It is a hardware block diagram of a machine tool and an image processing apparatus. It is a functional block diagram of an image processing apparatus. It is a figure which shows the illumination method of the target tool at the time of imaging. It is a figure which shows the image processing method. It is a flowchart which shows the process process of the tool shape data acquisition process before use. It is a flowchart which shows the process process of a tool inspection process. It is a figure which shows the illumination and the imaging method concerning the modification.

Hereinafter, an embodiment of the present invention will be described with reference to the drawings. The machine tool of the present embodiment is configured as a machining center for machining a work into a desired shape while appropriately exchanging tools.

FIG. 1 is a perspective view showing the appearance of the machine tool according to the embodiment. When the machine tool 1 is viewed from the front, the front-rear direction, the left-right direction, and the up-down direction are the Z-axis direction, the X-axis direction, and the Y-axis direction, respectively.
The machine tool 1 includes a processing device 2 and a tool accommodating device 4. A cover 6 (device housing) is provided so as to cover these devices. Inside the cover 6, a processing chamber 8 is provided on the right side when viewed from the front, and a storage chamber 10 is provided on the left side. Machining is performed by the processing apparatus 2 in the processing chamber 8. In the storage chamber 10, a plurality of tools are stored by the tool storage device 4, and tools are exchanged by an ATC (not shown) (details will be described later).

An operation panel 12 is provided on the right side surface of the cover 6. An image processing device 14 is connected to the processing chamber 8. The user can remotely monitor the work status of the machine tool 1 by the image processing device 14. The image processing device 14 may be a general laptop PC (Personal Computer) or a tablet computer. In the modified example, the image processing device may be configured as an internal device of the processing chamber 8.

FIG. 2 is a side view showing the internal configuration of the tool accommodating device 4. This figure corresponds to the left side view of the machine tool 1, but for convenience of explanation, the left side surface of the cover 6 is removed. In addition, a part of the magazine (described later) is partially cut out and displayed.

The tool accommodating device 4 has a disk-type magazine 20. A plurality of pots 22 are arranged along the outer peripheral surface of the magazine 20, and each of them is configured to be able to store the tool T. Each pot 22 coaxially supports the tool T, and a plurality of tools are radially supported around the rotation shaft 24 of the magazine 20. In the modified example, a chain type or other magazine may be adopted.

The magazine 20 rotates about the rotation shaft 24 and horizontally supports the tool T to be replaced at its front end position (right end position in FIG. 2). That is, the pot 22 of the magazine 20 functions as a “tool support portion” that supports the tool T (also referred to as “target tool Tx”) to be replaced in the storage chamber 10 in a standby state.

An opening 28 is provided in the partition wall 26 that separates the storage chamber 10 and the processing chamber 8, and a shutter 30 for opening and closing the opening 28 is provided. Further, an opening / closing mechanism 32 for opening / closing the opening 28 by moving the shutter 30 in the longitudinal direction of the target tool Tx is provided. ATC34 is provided in the accommodation chamber 10. The ATC 34 includes a tool T (also referred to as “pre-use tool Tp”) held in the accommodating chamber 10 in a standby state and a tool T (“used”) held by the tool spindle (not shown) in the machining chamber 8. Replace with "tool Tu"). The tool change is performed with the shutter 30 open.

The target tool Tx is horizontally supported as a replacement target in the storage chamber 10. The target tool Tx includes a pre-use tool Tp immediately before the tool change and a used tool Tu immediately after the tool change. In the present embodiment, an image of the pre-use tool Tp and an image of the used tool Tu are taken for the same tool. Based on the comparison between the image of the pre-use tool Tp and the image of the used tool Tu, the state of the used tool Tu (whether or not it is a defective tool, etc.) is determined. The details will be described later.

FIG. 3 is a perspective view schematically showing the configuration inside the accommodation chamber 10. FIG. 4 is a front view schematically showing the periphery of the boundary between the storage chamber 10 and the processing chamber 8.
As shown in FIG. 3, the target tool Tx is supported horizontally in the accommodation chamber 10. The shutter 30 is driven by the opening / closing mechanism 32 in the longitudinal direction of the target tool Tx to open / close the opening 28. The "longitudinal direction" of the target tool Tx is a direction along the axis of the pot 22 that supports the target tool Tx in the storage chamber 10, and corresponds to the "Z-axis direction". The "short direction" of the target tool Tx is a direction perpendicular to the longitudinal direction, and includes the "X-axis direction" and the "Y-axis direction". The opening / closing mechanism 32 includes a screw feed mechanism 33 and a servomotor 35 for driving the screw feed mechanism 33.

As shown in FIG. 4, the ATC 34 is arranged in the space between the target tool Tx and the shutter 30. The ATC 34 includes a main body 36 incorporating a motor and an arm 38 attached to a rotating shaft of the motor. The arm 38 has a shape symmetrical with respect to the rotation axis, and has grip portions 40 at both ends thereof. The grip portion 40 includes a fixed claw 42 and a movable claw 44. By driving the movable claw 44, the gripping operation by the gripping portion 40 can be realized.

The ATC 34 is provided with a translation mechanism for moving the arm 38 in the axial direction and a rotation mechanism for rotating the arm 38 around the axis. The motor includes a first motor that drives the translation mechanism and a second motor that drives the rotation mechanism. Since such a mechanism itself is known, detailed description thereof will be omitted.

When the ATC 34 is not activated, the arm 38 is in a state of being vertically oriented as shown in FIG. As a result, the ATC 34 is accommodated in the accommodation chamber 10 with the shutter 30 closed. When the ATC 34 is operated, the pre-use tool Tp stands by on one side (accommodation chamber 10 side) and the used tool Tu stands by on the other side (machining chamber 8 side) across the axis of the arm 38. At this time, the shutter 30 is released.

When the ATC 34 operates, the arm 38 rotates so that the pair of gripping portions 40 grip the pre-use tool Tp and the used tool Tu, respectively. At this time, the arm 38 temporarily straddles the opening 28. Further, by driving the translation mechanism and the rotation mechanism, the tool is detached and attached to the pot 22 and the tool spindle 37, and the tool can be replaced. Since the operation of such ATC itself is known, detailed description thereof will be omitted.

The camera 50 is arranged above the holding position of the target tool Tx, and the lighting device 52 is arranged below. The camera 50 includes an image sensor (imaging element) such as a CMOS (Complementary Metal Oxide Semiconductor) or a CCD (Charge-Coupled Device). The camera 50 in this embodiment has a resolution of about 1 million pixels (1224 × 1024) of the tool information storage unit. In addition, the camera 50 can acquire up to 80 captured images per second.

The lighting device 52 is fixed to the lower part of the shutter 30. The lighting device 52 functions as a “lighting unit” and illuminates the target tool Tx from diagonally below. The camera 50 functions as an "imaging unit" and images the target tool Tx from diagonally above. The camera 50 and the lighting device 52 are arranged on opposite sides of the target tool Tx. Due to the transmitted illumination by the illuminating device 52, the camera 50 can acquire a high-contrast captured image in which the contour position of the tool T can be easily grasped.

Returning to FIG. 3, the distance between the camera 50 and the target tool Tx (working distance: hereinafter also referred to as “WD”) is set so that the image pickup target portion of the target tool Tx can be accommodated on one screen (FIG. 3). 4). The "imaging target portion" means a portion (also referred to as an "inspection target portion") that needs to be inspected in order to determine whether or not the target tool Tx is a defective tool, and is set in advance. In the present embodiment, the image pickup target portion is from the base end to the cutting edge supported by the pot 22 in the target tool Tx. In the modified example, the part from the blade edge to the blade edge may be the imaging target portion.

As shown in FIG. 4, the rotation axis Lt of the tool spindle 37, the rotation axis Lx of the ATC 34, the moving direction of the shutter 30, and the longitudinal direction of the target tool Tx at the tool replacement standby position are parallel to each other (all are Z axes). It is designed to be parallel to).

Although not shown in FIGS. 3 and 4, each structure such as the main body 36 of the ATC 34, the opening / closing mechanism 32, and the camera 50 is stably fixed to the structure such as the wall surface or the beam in the accommodation chamber 10. Needless to say, there is.

FIG. 5 is a hardware configuration diagram of the machine tool 1 and the image processing device 14.
The machine tool 1 includes the above-mentioned machining device 2, the tool accommodating device 4, and the ATC 34, as well as the machining control device 60 and the operation control device 62. The machining control device 60 functions as a numerical control device and outputs a control signal to the machining device 2 according to a machining program. The machining apparatus 2 drives a tool spindle (not shown) according to an instruction from the machining control device 60 to machine a workpiece.

The operation control device 62 includes an operation panel 12 and controls the machining control device 60. The ATC 34 takes out the tool from the tool accommodating device 4 according to the exchange instruction from the machining control device 60, and exchanges the used tool Tu held on the tool spindle with the pre-use tool Tp taken out from the tool accommodating device 4.

The image processing device 14 mainly performs image processing such as tool shape recognition. As described above, the image processing device 14 may be configured as a part of the operation control device 62. Alternatively, the entire body including the image processing device 14 may be referred to as "machine tool 1".

FIG. 6 is a functional block diagram of the image processing device 14.
Each component of the image processing device 14 includes a CPU (Central Processing Unit), a computing unit such as various auxiliary processors, a storage device such as a memory and a storage device, hardware including a wired or wireless communication line connecting them, and a storage device. It is stored in and realized by software that supplies processing commands to the arithmetic unit. A computer program may be composed of a device driver, an operating system, various application programs located on the upper layers thereof, and a library that provides common functions to these programs. Each block described below shows a block for each function, not a configuration for each hardware.

The operation control device 62 and the processing control device 60 are also stored in the storage device and stored in the arithmetic unit, the hardware including the arithmetic unit such as a processor, the storage device such as memory and storage, and the wired or wireless communication line connecting them. The software or program that supplies the processing instructions may be realized on an operating system separate from the image processing unit 14.

The image processing device 14 includes a user interface processing unit 70, a data processing unit 72, a data storage unit 74, and a communication unit 76.
The user interface processing unit 70 accepts operations from the user and is in charge of processing related to the user interface such as image display and audio output. The communication unit 76 is in charge of communication with the operation control device 62. The data processing unit 72 executes various processes based on the data acquired by the user interface processing unit 70 and the data stored in the data storage unit 74. The data processing unit 72 also functions as an interface for the user interface processing unit 70, the data storage unit 74, and the communication unit 76. The data storage unit 74 stores various programs and setting data.

The user interface processing unit 70 includes an input unit 80 and an output unit 82.
The input unit 80 receives input from the user via a hard device such as a touch panel or a handle. The output unit 82 provides various information to the user via an image display or an audio output. The output unit 82 includes a notification unit 84. The notification unit 84 notifies the user of the occurrence of various events when a predetermined abnormal condition such as an abnormality of the tool to be replaced (a defective tool is detected) is satisfied (details will be described later).

The communication unit 76 includes a receiving unit 110 that receives data from the operation control device 62 and a transmitting unit 112 that transmits data and commands to the operation control device 62.

The data processing unit 72 includes a movement control unit 90, an imaging processing unit 92, a shape reproduction unit 94, a tool management unit 96, and a determination processing unit 98.
The movement control unit 90 drives and controls the opening / closing mechanism 32 to control the opening / closing of the shutter 30 (that is, the movement of the lighting device 52). The image pickup processing unit 92 controls the camera 50 to take an image of the target tool Tx. The shape reproduction unit 94 generates "tool shape data" which is data indicating the shape of the target tool Tx based on the captured image. The tool management unit 96 associates the tool ID and the tool shape data for each target tool Tx and registers them in the data storage unit 74.

The determination processing unit 98 determines whether or not an abnormality such as a defect, breakage, or wrapping of chips has occurred in the target tool Tx based on the captured image of the target tool Tx or based on the tool shape data (whether or not the tool is defective). ) Is judged. When the determination processing unit 98 determines that the target tool Tx is abnormal, the notification unit 84 notifies the user to that effect. The determination processing unit 98 may instruct the operation control device 62 to display the fact on the operation panel 12. When it is determined that the used tool Tu is a defective tool, the tool management unit 96 associates the information that the used tool Tu is a defective tool with the tool ID and registers it in the data storage unit 74 as the tool information.

The data storage unit 74 includes a tool information storage unit 100 and a shape data storage unit 102. The tool information storage unit 100 stores information (tool information) of each tool T stored in the magazine 20 in association with the tool ID. The tool information includes, for example, information such as the type, shape, size, and length of the tool. Furthermore, information such as cumulative usage time and cumulative usage count may be included. The data storage unit 74 also temporarily stores the captured image.

The tool information storage unit 100 updates the tool information every time the tool is replaced. If it is determined that the target tool Tx is a defective tool as described above, that fact is added as tool information. After the determination, the tool management unit 96 prohibits the use of the tool T on the defective tool, that is, the ATC 34 prohibits the tool from being replaced as the pre-use tool Tp.

The shape data storage unit 102 stores the tool shape data generated by the shape reproduction unit 94 in association with the tool ID. In this embodiment, tool shape data is created before and after tool replacement. Therefore, for each target tool Tx, the tool shape data of the pre-use tool Tp (hereinafter, also referred to as “pre-use tool shape data”) and the tool shape data of the used tool Tu (hereinafter, also referred to as “used tool shape data”). ) Is stored in association with the tool ID. The determination processing unit 98 can determine whether or not the used tool Tu is a defective tool by comparing the pre-use tool shape data and the used tool shape data for the same tool.

Next, a method of imaging the tool will be described.
FIG. 7 is a diagram showing an illumination method of the target tool Tx at the time of imaging. 7 (A) to 7 (C) show the imaging process. The upper part of each figure shows a side view, and the lower part shows a plan view. The alternate long and short dash line in the figure indicates a region where the contrast of the captured image is improved by illumination (that is, a region where the illumination is good for imaging: hereinafter also referred to as “recommended imaging region S”).

In this embodiment, a lighting device 52 having a predetermined size is used. On the other hand, as described above, the area from the base end to the cutting edge supported by the pot 22 in the target tool Tx is the image pickup target portion Ta. Therefore, as shown in FIG. 7A, when the target tool Tx becomes large to some extent, the image pickup target portion Ta cannot be contained in the image pickup recommended region S, and an image having high contrast is obtained over the entire image pickup target portion Ta. I can't. Therefore, it is conceivable to use a larger lighting device 52, but as already described, this leads to an increase in cost.

Therefore, in the present embodiment, the shutter 30 is opened and closed by the opening / closing mechanism 32, the lighting device 52 is moved, the target tool Tx is imaged a plurality of times, and the shape of the entire image target portion Ta is recognized based on the plurality of captured images. The method is adopted. Hereinafter, a part of the region of each of the plurality of captured images, that is, a part of the target tool Tx is referred to as a “partial image”. When the lighting device 52 is moved, the image pickup processing unit 92 captures an image of the target tool Tx a plurality of times before and after the movement and at least one of the moving processes, and acquires a plurality of captured images.

Specifically, the camera 50 captures an image of the pre-use tool Tp a plurality of times when the shutter 30 is driven in the opening direction (that is, when the shutter 30 moves in the opening direction due to the opening operation of the opening / closing mechanism 32). Further, the camera 50 captures an image of the used tool Tu a plurality of times when the shutter 30 is driven in the closing direction (that is, when the shutter 30 moves in the closing direction due to the closing operation of the opening / closing mechanism 32). The image of the pre-use tool Tp is executed immediately before the tool change by the ATC34, and the image of the used tool Tu is executed immediately after the tool change by the ATC34.

That is, regarding the imaging of the pre-use tool Tp, an image is taken at the opening operation starting point of the opening / closing mechanism 32 (FIG. 7 (A)), and further, an image is taken at the opening operation intermediate point and the opening operation end point of the opening / closing mechanism 32 (FIG. 7 (B). ), (C)). The "open operation start point" here corresponds to the closed state of the shutter 30, the "open operation intermediate point" corresponds to the intermediate open state of the shutter 30, and the "open operation end point" corresponds to the fully open state of the shutter 30. To do. The "opening operation intermediate point" may be a temporary stop point of the lighting device 52 or a moving passing point. It is preferable to set it as a pause point in order to acquire an image with less noise due to a change in lighting. The "open operation end point" is also the closing movement starting point of the lighting device 52. By narrowing the exposure time of the camera 50, the lighting device 52 may be imaged without pausing at the opening operation intermediate point.

In the example of FIG. 7, an image is taken once at the opening operation starting point of the opening / closing mechanism 32 (FIG. 7 (A)), and another image is taken at the opening operation intermediate point of the opening / closing mechanism 32 (FIG. 7 (B)). Another image is taken at the end point of the open operation of 32 (FIG. 7 (C)). Of these three captured images acquired when the shutter 30 is opened, the first image is the first pre-use image P1, the second image is the second pre-use image P2, and the third image is the third use. It is a front image P3.

Since the contrast becomes higher as the lighting device 52 is located closer to the front surface, the portion corresponding to the recommended imaging region S is different in each pre-use image. In the first pre-use image P1, the portion closer to the proximal end side of the imaging target portion Ta fits in the imaging recommended region S. In the second pre-use image P2, the intermediate portion of the image pickup target portion Ta falls within the image pickup recommended area S. In the third pre-use image P3, the portion closer to the tip of the imaging target portion Ta fits in the imaging recommended region S. Since the amount of movement of the lighting device 52 between the front and rear imaging is smaller than the length of the recommended imaging region S, the recommended imaging region S partially overlaps the front and rear pre-use images.

FIG. 8 is a diagram showing an image processing method. FIG. 8A shows an image extraction method, and FIG. 8B shows an image composition method.
The imaging processing unit 92 extracts partial images having relatively high contrast from the pre-use images P1 to P3 (FIG. 8A), synthesizes the extracted plurality of partial images, and synthesizes the entire target tool Tx. An image is generated (FIG. 8 (B)).

That is, the imaging processing unit 92 extracts the partial image Pb1 that fits in the recommended imaging region S for the first pre-use image P1, extracts the partial image Pb2 that fits in the recommended imaging region S for the second pre-use image P2, and third. For the pre-use image P3, a partial image Pb3 that fits in the recommended imaging region S is extracted (FIG. 8 (A)). Then, by connecting and synthesizing these partial images Pb1 to Pb3, the entire image Pa of the target tool Tx is generated (FIG. 8 (B)). As a result, a high-quality image with high contrast can be obtained as the overall image Pa. The imaging processing unit 92 specifies the contour of the pre-use tool Tp (imaging target unit Ta) based on the entire image Pa.

Specifically, the silhouette of the target tool Tx projected by the lighting device 52 is displayed as the entire image Pa of the imaging target portion Ta. The imaging processing unit 92 sets a scanning line in the X-axis direction, and sets a point located at the boundary from a dark region (silhouette region where the target tool Tx exists) to a bright region (region where the target tool Tx does not exist) as an edge point. To detect. The imaging processing unit 92 detects a plurality of edge points while shifting the scanning lines at a constant pitch, and identifies the contour of the target tool Tx by connecting these edge points. The shape reproduction unit 94 generates tool shape data (tool shape data before use) based on the specified contour.

On the other hand, the image processing of the used tool Tu is the same as that of the pre-use tool Tp, except that the driving direction of the shutter 30 (that is, the moving direction of the lighting device 52) at the time of imaging is different. The imaging process of the used tool Tu is executed following the tool exchange process with the pre-use tool Tp.

That is, regarding the imaging of the used tool Tu, the image is taken at the closing operation starting point of the opening / closing mechanism 32 (FIG. 7 (C)), and further at the closing operation intermediate point and the closing operation end point of the opening / closing mechanism 32 (FIG. 7 (B). ), (A)). The "closed operation start point" here corresponds to the fully open state of the shutter 30, the "closed operation intermediate point" corresponds to the intermediate closed state of the shutter 30, and the "closed operation end point" corresponds to the closed state of the shutter 30. To do. The “closing operation intermediate point” may be a temporary stop point of the lighting device 52 or a moving passing point. It is preferable to set it as a pause point in order to acquire an image with less noise due to a change in lighting. The “closed operation end point” is also the open movement starting point of the lighting device 52.

An image is taken once at the closing operation starting point of the opening / closing mechanism 32 (FIG. 7 (C)), another image is taken at the closing operation intermediate point of the opening / closing mechanism 32 (FIG. 7 (B)), and at the closing operation end point of the opening / closing mechanism 32. Another image is taken (FIG. 7 (A)). Of these three captured images acquired when the shutter 30 is closed, the first image is the first used image, the second image is the second used image, and the third image is the third used image. Is.

The image processing method (image extraction method, image composition method) of the used tool Tu is the same as that of the pre-use tool Tp. A high-contrast partial image is extracted from each used image, and the partial images are combined to obtain an entire image. The detailed description thereof will be omitted. The imaging processing unit 92 identifies the contour of the used tool Tu (imaging target unit Ta) based on the entire image. The shape reproduction unit 94 generates tool shape data (used tool shape data) based on the specified contour.

The determination processing unit 98 compares the pre-use tool shape data and the used tool shape data for the same tool. In the determination processing unit 98, when the similarity between the shape of the tool before use and the shape of the used tool, particularly the similarity of the contour is equal to or less than a predetermined value, the target tool Tx has a defect or the like, that is, the target tool. It is determined that Tx is a defective tool. At this time, the notification unit 84 causes the user to display an alert screen indicating that a defective tool has been detected. Alternatively, a sound such as a buzzer sound may be generated.

FIG. 9 is a flowchart showing the processing process of the pre-use tool shape data acquisition process.
This process is executed when the pre-use tool Tp is held horizontally in the storage chamber 10 in the standby state prior to the tool change. At this time, the shutter 30 is in the closed state, and the lighting device 52 is at the opening movement starting point.

The image pickup processing unit 92 turns on the tool change prohibition flag predetermined prior to this processing (S10). It is prohibited that the tool is changed by the ATC 34 during the imaging of the pre-use tool Tp. Subsequently, the pre-use tool Tp is imaged by the camera 50 (S11). The image acquired at this time is stored as the first pre-use image P1. Subsequently, the movement control unit 90 operates the opening / closing mechanism 32 to move the shutter 30 in the opening direction (S12). As a result, when the lighting device 52 reaches the next lighting position (Y in S14), the shutter 30 is temporarily stopped (S16). The image pickup processing unit 92 takes an image of the pre-use tool Tp with the camera 50 (S18). The image acquired at this time is stored as the second pre-use image P2.

The processes of S12 to S18 are repeated until the set number of imaging is completed (N in S20). In the present embodiment, the number of times of setting is set to 3, and if the third pre-use image P3 is acquired, the imaging is completed, but the number of times of setting may be changed depending on the length of the tool. When the set number of imaging is completed (Y in S20), the tool change prohibition flag is turned off (S22). Upon completion of this imaging, the tool change by the ATC 34 is permitted. In other words, the imaging process for the pre-use tool Tp is executed while the tool change prohibition flag is turned on.

The image pickup processing unit 92 extracts partial images Pb1 to Pb3 having high contrast from each of the plurality of pre-use images P1 to P3 described above (S24), and generates an entire image Pa by synthesizing these (S24). The shape reproduction unit 94 generates pre-use tool shape data based on the overall image Pa (S28). The tool management unit 96 stores the pre-use tool shape data in the shape data storage unit 102 in association with the tool ID (S30). This pre-use tool shape data is used for tool inspection, which will be described later.

FIG. 10 is a flowchart showing the processing process of the tool inspection process.
This process is executed when the used tool Tu is held horizontally in the storage chamber 10 in the standby state prior to storing the tool after the tool is replaced. At this time, the shutter 30 is in the fully open state, and the lighting device 52 is at the closing movement starting point.

The image pickup processing unit 92 takes an image of the used tool Tu with the camera 50 (S40). The image acquired at this time is stored as the first used image. Subsequently, the movement control unit 90 operates the opening / closing mechanism 32 to move the shutter 30 in the closing direction (S42). As a result, when the lighting device 52 reaches the next lighting position (Y in S44), the shutter 30 is temporarily stopped (S46). The image pickup processing unit 92 takes an image of the used tool Tu with the camera 50 (S48). The image acquired at this time is stored as a second used image.

The processes of S42 to S48 are repeated until the set number of imaging is completed (N in S50). In the present embodiment, the number of times of setting is three, and when the third used image is acquired, the imaging is completed, but the number of times of setting may be changed depending on the length of the tool. When the set number of imaging is completed (Y in S50), the imaging processing unit 92 extracts a high-contrast partial image from each of the plurality of used images described above (S52), and combines these to obtain the entire image. Generate (S54). The shape reproduction unit 94 generates used tool shape data based on the entire image (S56). The tool management unit 96 temporarily stores the used tool shape data in the shape data storage unit 102 (S58).

The determination processing unit 98 reads out the used tool shape data and the pre-use tool shape data having the same tool ID (S60), and compares the tool shape data (S62). That is, the shape of the tool before use and the shape of the used tool are compared for the same tool. At this time, if the similarity between the used tool shape and the pre-use tool shape is a defective tool of a predetermined value or less (Y in S64), the notification unit 84 is notified to that effect (S66). That is, the notification unit 84 displays the alert screen. If it is not a defective tool (N in S64), the process in S66 is skipped.

In the present embodiment, the used tool Tu, which is determined to be a defective tool after the tool is replaced, is also stored in the magazine 20, but the tool is prohibited from being used until the predetermined maintenance is performed. The information that the tool is prohibited is stored in association with the tool ID.

In general, a tool has an upper limit of the number of times of use and the time of use (also referred to as "quality assurance parameter") in order to ensure its quality. Tools whose quality assurance parameters exceed the upper limit are prohibited from use, and tools of the same type (sub-tools) prepared separately and stored in the magazine 20 are used. As a result, the mass production process by the processing apparatus 2 is not hindered. In the present embodiment, even if the quality assurance parameter does not exceed the upper limit value, when a defective tool is detected, the sub tool is used while managing the corresponding tool as prohibition of use.

The machine tool 1 has been described above based on the embodiment.
In the present embodiment, the lighting device 52 is fixed to the shutter 30, and the lighting device 52 is moved in the longitudinal direction of the target tool Tx as the shutter 30 is opened and closed to perform imaging a plurality of times. Therefore, it is not necessary to adopt a large and expensive lighting device 52. That is, according to the present embodiment, it is possible to secure the contrast of the captured image regardless of the tool length while suppressing the cost, and it is possible to detect the shape of the tool with sufficient accuracy.

Since the tool inspection process is performed with the shutter 30 closed, new machining can be executed in the processing device 2 during that time. That is, since image processing can be performed during processing, there is an advantage that each processing does not interfere with each other.

The present invention is not limited to the above-described embodiment or modification, and the components can be modified and embodied within a range that does not deviate from the gist. Various inventions may be formed by appropriately combining a plurality of components disclosed in the above embodiments and modifications. In addition, some components may be deleted from all the components shown in the above embodiments and modifications.

In the above embodiment, a configuration in which a high-contrast overall image is acquired by imaging and synthesizing the image pickup target portion Ta of the target tool Tx three times is illustrated. That is, the lighting device 52 was moved regardless of the length of the target tool Tx, and the number of times of imaging by the camera 50 was set to a plurality of times. Therefore, when the target tool Tx is short, the imaging may be missed.

In the modified example, when the imaging target portion Ta is short enough to fit in the recommended imaging region S, the number of imagings by the camera 50 may be one. That is, the pre-use tool Tp may be limited to one imaging at the opening movement starting point of the lighting device 52. The used tool Tu may be imaged only once at the closing end point of the lighting device 52.

The tool length information is stored in the tool information storage unit 100 in association with the tool ID. The movement control unit 90 may read out the tool information corresponding to the target tool Tx, and may limit the number of imaging times to one when the tool length is equal to or less than the first reference value. The "first reference value" may be the length of the recommended imaging region S, or may be shorter than that (see FIG. 7).

Further, when each part of the image pickup target part Ta fits in the image pickup recommended area S by two times of imaging, the number of times of imaging may be set to two times. In that case, the pre-use tool Tp may be imaged at the opening movement starting point and the opening movement end point of the lighting device 52. Further, the used tool Tu may be imaged at the closing movement starting point and the closing moving end point of the lighting device 52.

On the contrary, if the imaging target portion Ta is so long that a part of the three imaging images does not fit in the recommended imaging region S, the number of imaging times may be three or more. The movement control unit 90 may set the number of stops of the shutter 30 according to the length of the target tool Tx (the length of the image pickup target unit Ta). The image pickup processing unit 92 may take an image of the target tool Tx every time the movement of the lighting device 52 is stopped.

In the above embodiment, the shutter 30 is temporarily stopped at the moving intermediate point of the lighting device 52, and the target tool Tx is imaged with the lighting device 52 stopped. In the modified example, the opening / closing speed of the shutter 30 (that is, the moving speed of the lighting device 52) may be reduced at the moving intermediate point of the lighting device 52 to image the target tool Tx. That is, the image may be taken while moving the lighting device 52 at a low speed.

In that case, the image may be taken a plurality of times (many times) based on the shutter speed. For each of the plurality of captured images (images 1 to n), a plurality of regions (regions 1 to m) may be set in the same manner, and each region may be acquired as a partial image. Then, the partial image having the highest contrast for each region 1 to m may be extracted from the partial images included in the plurality of images 1 to n, and the extracted partial images may be combined to form an entire image.

FIG. 11 is a diagram showing an illumination and an imaging method according to a modified example. 11 (A) and 11 (B) show the imaging process. The alternate long and short dash line in the figure indicates the imaging region Sp by the camera 50, and the alternate long and short dash line indicates the recommended imaging region S where high contrast can be obtained by the lighting device 52.

Although not described in the above embodiment, as shown in FIG. 11A, the target tool Tx includes a holder Th supported by the pot 22 and a blade Tb coaxially attached to the holder Th. The protruding length of the blade Tb from the holder Th is called an overhang lo. The camera 50 has an angle of view sufficient to accommodate the entire target tool Tx in the imaging region Sp.

In this modification, the camera 50 performs the first imaging of the pre-use tool after the shutter 30 starts moving in the opening direction and then moves a predetermined distance x 1 (FIG. 11 (A)). Then, after the moving distance of the shutter 30 has moved by a predetermined distance x 2, the camera 50 performs the second imaging. The distance x1 is set so that the recommended imaging region S includes at least the tip position of the holder Th (that is, the base end position where the blade Tb protrudes). The distance x2 is set to be at least half the length of the blade portion of the target tool Tx (more specifically, the overhang lo).

Then, as in the above embodiment, the partial images corresponding to the recommended imaging region S are acquired for each of the captured images obtained by these two imagings, and they are connected and combined to form an image of the blade portion and its surroundings. To generate. According to this modification, it is possible to obtain a high-quality image with high contrast by focusing on the blade portion (exposed portion of the blade Tb) of the target tool Tx.

In this modification, the pre-use tool is illustrated, but a good quality image can be obtained for the used tool as well. In that case, the camera 50 captures an image of the used tool immediately after replacement when the shutter 30 moves in the closing direction. The first imaging is performed before the shutter 20 starts moving in the closing direction or after moving a predetermined distance in the closing direction. At this time, at least the tip position of the blade Tb is included in the recommended imaging region S. After the first imaging, the camera 50 performs the second imaging after the moving distance of the shutter 30 has moved by half or more (that is, overhang or more) of the length of the blade portion of the tool.

Then, for each of the captured images obtained by these two imagings, a partial image corresponding to the recommended imaging region S is acquired, and by connecting and synthesizing them, an image of the blade portion and its surroundings can be generated.

In another modification, for the same tool, the shutter 30 is first imaged (pre-use imaging) for the pre-use tool before the shutter 30 is opened (before moving), and after the used tool is replaced, the shutter 30 is taken. A second imaging (imaging after use) may be performed after the is closed. Here, the image taken by pre-use imaging is also referred to as "pre-use captured image", and the image taken after use is also referred to as "post-use captured image". In this case, the presence or absence of breakage of the target tool Tx may be detected depending on whether or not the captured image after use includes the tool as in the captured image before use. That is, similarly, breakage detection may be performed when the tool is not included. By moving the lighting device 52 together with the shutter 30, it is possible to reduce the adhesion of mist and the like from the processing chamber 8 to the lighting device 52.

In the above embodiment, the configuration in which the camera 50 is fixed, the lighting device 52 is moved, and the target tool Tx is imaged a plurality of times is illustrated. In the modified example, both the camera 50 and the lighting device 52 may be moved to image the target tool Tx a plurality of times. By always arranging the camera 50 and the lighting device 52 on the opposite side of the target tool Tx, it is possible to acquire a high-quality image with higher contrast. In that case, a moving mechanism for moving the camera 50 in the longitudinal direction of the target tool Tx is provided.

In the above embodiment, the configuration in which the determination processing unit 98 determines the defect of the target tool Tx is illustrated. In the modification, the tool shape data generated by the shape reproduction unit 94 for the pre-use tool Tp and the used tool Tu may be drawn and displayed in comparison with the output unit 82. The user may visually compare the tool shapes before and after use to determine whether or not the target tool Tx is a defective tool.

In the above embodiment, each target tool Tx is imaged before and after tool replacement (that is, before and after machining) to generate tool shape data. Then, by comparing the pre-use tool shape data and the used tool shape data for each tool, it was determined whether or not there was an abnormality such as a defect. In the modified example, the defective tool may be determined by using the tool image itself without generating the tool shape data (tool contour data). That is, it may be determined whether or not the used tool Tu is a defective tool by comparing the pre-use tool image and the used tool image for each target tool Tx.

In the above embodiment, each target tool Tx is imaged immediately before and after machining, and the state of the used tool Tu (whether or not it is a defective tool) is determined based on those images. That is, an example is shown in which the captured image immediately before use is used as a "reference image" as a criterion for judgment. In the modified example, the reference image may be stored as basic data at the time of tool registration before the start of the first use of the tool. However, in order to perform more accurate shape detection (shape comparison) by making the imaging environment such as the lighting state the same, it is preferable to compare the image immediately before machining and the image immediately after machining.

In the above embodiment, an example is shown in which the imaging unit (camera 50) is arranged above the target tool Tx and the lighting unit (illuminating device 52) is arranged below the target tool Tx. On the contrary, in the modified example, the imaging unit may be arranged below the target tool Tx, and the illumination unit may be arranged above the target tool Tx. From the viewpoint of preventing contamination of the camera lens, the arrangement of the above embodiment is preferable. This is because if the camera is placed below the target tool, for example, if the target tool is a used tool, coolant may drip from the used tool and contaminate the camera lens. According to the above embodiment, there is no such concern.

In the above embodiment, the pot 22 of the magazine 20 is used as the “tool support portion”, and the configuration in which the target tool Tx is supported in the storage chamber 10 in the standby state is illustrated. In the modified example, the ATC 34 (more specifically, the arm 38) may function as a "tool support portion". That is, the target tool before or after the tool change may be supported by the ATC, and the illumination unit may be moved by the shutter and the image pickup process may be performed by the image pickup unit.

In the above embodiment, the ATC 34 is illustrated as the "tool transport unit", but a tool transport mechanism for transporting tools between the processing chamber and the accommodating chamber may be provided without having a tool changing function.

In the above embodiment, the machining center is illustrated as the machine tool 1, but it goes without saying that the tool inspection technique can be applied to the turning center and the multi-tasking machine.

1 Machinery, 2 Machining equipment, 4 Tool accommodating equipment, 6 Covers, 8 Machining chambers, 10 Accommodating chambers, 12 Operation panel, 14 Image processing equipment, 20 Magazines, 22 pots, 26 partition walls, 28 openings, 30 shutters, 32 opening and closing Mechanism, 33 screw feed mechanism, 34 ATC, 35 servo motor, 38 arm, 40 grip part, 50 camera, 52 lighting device, 60 processing control device, 62 operation control device, 70 user interface processing unit, 72 data processing unit, 74 Data storage unit, 76 communication unit, 80 input unit, 82 output unit, 84 notification unit, 90 movement control unit, 92 imaging processing unit, 94 shape reproduction unit, 96 tool management unit, 98 judgment processing unit, 100 tool information storage unit , 102 Shape data storage unit, Pa whole image, Pb1 partial image, Pb2 partial image, Pb3 partial image, S imaging recommended area, T tool, Ta imaging target part, Tp pre-use tool, Tu used tool, Tx target tool.

Claims (10)

A storage room that accommodates multiple tools and
A processing room where machining with tools is executed, and
A shutter that opens and closes an opening provided in a partition wall between the storage chamber and the processing chamber,
A tool support portion that supports the tool to be replaced in the storage chamber,
An imaging unit arranged in the containment chamber and
An illumination unit fixed to the shutter and illuminating the tool supported by the tool support unit,
An opening / closing mechanism that opens and closes the opening by moving the shutter in the longitudinal direction of the tool.
With
A machine tool that moves the lighting unit integrally with the shutter to image the tool. The machine tool according to claim 1, wherein the lighting unit is located on the opposite side of the tool from the imaging unit. The machine tool according to claim 1 or 2, wherein when the shutter is moved, the imaging unit captures an image of the tool a plurality of times before and after the movement and at least one of the moving processes. A data storage unit that stores captured images and
An image pickup processing unit that executes a predetermined process based on the captured image, and
With
The image pickup processing unit
For multiple images obtained by imaging the same tool multiple times, partial images with relatively high contrast are extracted.
The machine tool according to claim 3, wherein a plurality of extracted partial images are combined to generate an entire image of the tool. The imaging unit captures an image of the pre-use tool immediately before replacement when the shutter moves in the opening direction.
The machine tool according to claim 3 or 4, wherein the imaging unit performs the second imaging after the first imaging is performed and the moving distance of the shutter moves by half or more of the length of the blade portion of the tool. .. The machine tool according to claim 5, wherein the imaging unit performs the first imaging after the shutter starts moving and moves a predetermined distance. The machine tool according to any one of claims 3 to 6, wherein the imaging unit captures an image of a used tool immediately after replacement a plurality of times when the shutter moves in the closing direction. Further provided with a determination processing unit that executes a predetermined determination process based on the captured image,
The machine tool according to claim 7, wherein the determination processing unit determines the state of the used tool based on an image of the used tool and a reference image acquired in advance for the same tool as the used tool. .. Further provided with a determination processing unit that executes a predetermined determination process based on the captured image,
The imaging unit captures an image of the pre-use tool immediately before replacement a plurality of times when the shutter moves in the opening direction, and a plurality of images of the used tool immediately after replacement when the shutter moves in the closing direction. Imaged once,
The determination processing unit determines the state of the used tool based on the image of the used tool and the image of the pre-use tool imaged for the same tool as the used tool, claim 3 or 4. Machine tools listed in. A storage room that accommodates multiple tools and
A processing room where machining with tools is executed, and
A shutter that opens and closes an opening provided in a partition wall between the storage chamber and the processing chamber,
A tool support portion that supports the tool to be replaced in the storage chamber,
An imaging unit arranged in the containment chamber and
An illumination unit fixed to the shutter and illuminating the tool supported by the tool support unit,
An opening / closing mechanism that opens and closes the opening by moving the shutter in the longitudinal direction of the tool.
A machine tool.

Images