JP2003245846A - Cutting tool life diagnostic apparatus - Google Patents
Cutting tool life diagnostic apparatusInfo
- Publication number
- JP2003245846A JP2003245846A JP2002048542A JP2002048542A JP2003245846A JP 2003245846 A JP2003245846 A JP 2003245846A JP 2002048542 A JP2002048542 A JP 2002048542A JP 2002048542 A JP2002048542 A JP 2002048542A JP 2003245846 A JP2003245846 A JP 2003245846A
- Authority
- JP
- Japan
- Prior art keywords
- cutting tool
- life
- motor
- waveform
- power waveform
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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- Machine Tool Sensing Apparatuses (AREA)
- Drilling And Boring (AREA)
Abstract
Description
【０００１】[0001]
【発明の属する技術分野】本発明は、ワークを加工する
刃具の寿命を診断する刃具寿命診断装置に関する。BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a tool life diagnosing device for diagnosing the life of a tool for machining a work.
【０００２】[0002]
【従来の技術】従来、刃具寿命診断装置として、刃具の
駆動軸に振動計を接続し、切削加工中の振動レベルが正
常時の振動レベルの最大値（判定レベル）を超えたと
き、刃具に欠けが発生したと判断する振動診断方式を採
用した装置が知られている。2. Description of the Related Art Conventionally, as a cutting tool life diagnosing device, a vibrometer is connected to the driving shaft of the cutting tool, and when the vibration level during cutting exceeds the maximum value (judgment level) of the vibration level during normal cutting, A device that employs a vibration diagnosis method that determines that a chip has occurred is known.
【０００３】[0003]
【発明が解決しようとする課題】しかしながら、高精度
の品質が要求される製品例えば油圧制御ソレノイドバル
ブのスリーブでは、十分に高い円筒度および面粗さが要
求されるが、上記のような振動診断方式では、上記判定
レベル以下において発生する刃具の寿命に基づく異常
（欠け以外の寿命に基づく異常）について診断すること
ができないため、円筒度不良および面粗さ不良を検出で
きないという問題があった。However, products such as sleeves for hydraulically controlled solenoid valves, which require high precision quality, are required to have sufficiently high cylindricity and surface roughness. In the method, there is a problem in that it is not possible to diagnose abnormalities due to the life of the cutting tool (abnormalities due to the life other than chipping) that occur below the determination level, and therefore it is not possible to detect cylindricity defects and surface roughness defects.
【０００４】そのため、加工品質維持のため刃具の交換
タイミングを早めるようにしていたが、このことは、刃
具の正規寿命（当該刃具によって加工可能なワークの総
数量を基準とした寿命）前に刃具を交換することになり
刃具費の増大を招いていた。Therefore, in order to maintain the quality of processing, the timing of exchanging the cutting tool has been advanced, but this means that the cutting tool can be replaced before the normal service life of the cutting tool (the service life based on the total number of workpieces that can be processed by the cutting tool). Had to be replaced, leading to an increase in blade cost.
【０００５】そこで、本発明者らは、刃具費の低減と加
工品質維持との両立を図る方策について鋭意検討をした
結果、刃具に駆動力を与えるモータの供給電力量（有効
電力量）と刃具の寿命とに相関関係があり、刃具の加工
ワーク数の増加（通常、この増加にしたがって刃具は劣
化し円筒度および面粗さが低下してゆく）に伴いワーク
加工中の有効電力波形が全域にわたって増大側にシフト
してゆくとともに、この有効電力波形の特異的変化箇所
によって、予測に反した刃具の寿命到来(刃具のばらつ
き、あるいはワークの異常設定等)に起因する円筒度お
よび面粗さの品質異常を検出できることを見出した。Therefore, the inventors of the present invention have made extensive studies as to measures for achieving both reduction of cutting tool cost and maintenance of machining quality, and as a result, the amount of electric power (effective amount of power) supplied to a motor for giving a driving force to the cutting tool and the cutting tool. Of the effective power waveform during the machining of the workpiece as the number of workpieces processed by the blade increases (usually, the blade deteriorates and the cylindricity and surface roughness decrease with this increase). The eccentricity and surface roughness caused by the unexpected end of tool life (cutting tool variation, abnormal workpiece setting, etc.) due to the unique change point of the active power waveform. It has been found that the quality abnormality of can be detected.
【０００６】本発明は、上記のような知見に基づきなさ
れたものであり、モータの有効電力波形に基づいて刃具
を交換すべきタイミングを正確に把握でき、刃具費の低
減と加工品質維持の両立を図ることができる刃具寿命診
断装置を提供することを目的とする。The present invention has been made on the basis of the above knowledge, and it is possible to accurately grasp the timing at which the cutting tool should be replaced based on the effective power waveform of the motor, and it is possible to reduce the cutting tool cost and maintain the processing quality. It is an object of the present invention to provide a cutting tool life diagnosing device capable of achieving the above.
【０００７】[0007]
【課題を解決するための手段】本発明の刃具寿命診断装
置によると、新品刃具によるワーク加工中のモータ有効
電力波形から当該刃具の寿命を示す基準有効電力波形を
設定し、この基準有効電力波形と現に測定された有効電
力波形とをパターン認識により比較して当該刃具の寿命
を判定するようにしたため、刃具の欠けの他、刃具の劣
化等に基づく円筒度および面粗さの品質異常も検出可能
となり、刃具を交換すべきタイミングを正確に把握で
き、刃具費の低減と加工品質維持の両立を図ることがで
きる。According to the tool life diagnosing device of the present invention, a reference active power waveform indicating the life of the tool is set from the motor active power waveform during machining of a workpiece by a new tool, and the reference active power waveform is set. And the actual measured active power waveform are compared by pattern recognition to determine the service life of the cutting tool, so in addition to chipping of the cutting tool, abnormalities in cylindricity and surface roughness due to deterioration of the cutting tool are also detected. This makes it possible to accurately grasp the timing at which the cutting tool should be replaced, and it is possible to reduce the cutting tool cost and maintain the processing quality.
【０００８】また、前記パターン認識形出力監視装置に
より、当該刃具に寿命がきた旨の警報がされるため、速
やかに加工停止、刃具交換など適切な処置をとることが
可能となり、大量の不良品の発生につながる事態に対し
て早期の対応をすることができるようになる。Further, since the pattern recognition type output monitoring device warns that the cutting tool has reached the end of its life, it is possible to promptly take appropriate measures such as machining stop and replacement of the cutting tool, and a large amount of defective products. It becomes possible to take an early response to the situation that leads to the occurrence of.
【０００９】[0009]
【発明の実施の形態】以下、本発明の実施形態を図面に
基づいて説明する。BEST MODE FOR CARRYING OUT THE INVENTION Embodiments of the present invention will be described below with reference to the drawings.
【００１０】図１は、一実施形態に係る刃具寿命診断装
置が適用された単軸刃具診断システムの構成図を示す。
この単軸刃具診断システムは、油圧制御ソレノイドバル
ブのスリーブをワークとし、図２に示すようなスリーブ
加工ラインにおける仕上げ加工機に組み込まれる。FIG. 1 is a block diagram of a single-axis cutting tool diagnostic system to which a cutting tool life diagnosing apparatus according to an embodiment is applied.
This single-axis cutting tool diagnostic system uses a sleeve of a hydraulically controlled solenoid valve as a work and is incorporated in a finishing machine in a sleeve processing line as shown in FIG.
【００１１】図１において、１は、治具２に固定された
油圧制御ソレノイドバルブのスリーブ（ワーク）を表
す。油圧制御ソレノイドバルブは、図３に示すように、
コイル３への通電の有無によってスプール４がスリーブ
１内を軸方向へ移動し、油圧を制御するバルブであり、
スリーブ１には、製造時に円筒度が例えば８μｍ以下、
面粗さが例えば２．４μＲｚ以下の品質が要求されてい
る。５は、ワーク１を切削加工する刃具例えばダイヤリ
ーマを表す。刃具５は、主軸６の先端に取り付けられ、
主軸６は、ベルト７を介してモータ例えば三相誘導電動
機８によって駆動される。そして、主軸６およびモータ
８は、ワーク１に対して進退可能なスライド９の上に固
定されている。In FIG. 1, reference numeral 1 denotes a sleeve (workpiece) of a hydraulic control solenoid valve fixed to a jig 2. The hydraulic control solenoid valve, as shown in FIG.
The spool 4 is a valve that controls the hydraulic pressure by moving the spool 4 in the sleeve 1 in the axial direction depending on whether or not the coil 3 is energized.
The sleeve 1 has a cylindricity of, for example, 8 μm or less when manufactured,
A surface roughness of, for example, 2.4 μRz or less is required. Reference numeral 5 represents a cutting tool for cutting the work 1, for example, a diarea. The cutting tool 5 is attached to the tip of the main shaft 6,
The main shaft 6 is driven by a motor, for example, a three-phase induction motor 8 via a belt 7. The spindle 6 and the motor 8 are fixed on a slide 9 that can move forward and backward with respect to the work 1.
【００１２】刃具寿命診断装置１０は、モータ８の電流
および電圧を検出してモータ８の有効電力波形を測定す
るモータ電力量検出装置１１を備える。モータ電力量検
出装置１１は、刃具５の寿命診断開始時に、主軸６に新
品刃具５を取り付けてワーク１を切削加工したときの有
効電力波形を測定する。この測定された有効電力波形
は、パターン認識形出力監視装置１２において当該刃具
５の使用期間（寿命期間）全体における初期波形として
扱われ、パターン認識形出力監視装置１２は、この初期
波形から当該刃具５の寿命を示す基準有効電力波形を設
定し記憶する。ここで、初期波形は、図４に示すよう
に、スリーブ１の刃具加工部位Ａ〜Ｆに応じて変化する
有効電力（％）で表される。この有効電力は、切削負荷
と１対１の関係をもち、切削負荷が大きいときには大き
く、小さいときには小さな値となる。また、基準有効電
力波形は、図５に、「特徴１」として示すように、刃具
磨耗（加工数）の増大にしたがって有効電力波形が相似
的に増大側にシフトするとともに円筒度および面粗さが
悪化してゆく点、「特徴２」として示すように、円筒度お
よび面粗さの品質異常が有効電力波形の特異的変化によ
って検出できる点、および、刃具５に欠けが生じた場合
には有効電力が著しく減少する点に着目し、図６に示す
ような、初期波形を増大側に所定倍(例えば１．４倍)し
て得られる上限基準波形と、減少側に所定倍（例えば
０．７倍）して得られる下限基準波形とで構成される。The cutting tool life diagnosing device 10 comprises a motor power amount detecting device 11 for detecting the current and voltage of the motor 8 and measuring the active power waveform of the motor 8. The motor power amount detection device 11 measures the effective power waveform when the new blade 5 is attached to the spindle 6 and the work 1 is cut at the start of the life diagnosis of the blade 5. The measured active power waveform is treated as an initial waveform in the entire usage period (life period) of the cutting tool 5 by the pattern recognition type output monitoring apparatus 12, and the pattern recognition type output monitoring apparatus 12 uses the initial waveform as the initial waveform. The reference active power waveform indicating the life of 5 is set and stored. Here, as shown in FIG. 4, the initial waveform is represented by active power (%) that changes according to the cutting tool processing parts A to F of the sleeve 1. This active power has a one-to-one relationship with the cutting load, and has a large value when the cutting load is large and a small value when the cutting load is small. In addition, as shown as "feature 1" in FIG. 5, the reference active power waveform is similar to the active power waveform that shifts toward the increasing side as the blade wear (number of machining) increases, and the cylindricity and surface roughness are increased. Is deteriorated, as shown in "Characteristic 2", abnormalities in cylindricity and surface roughness can be detected by a specific change in the active power waveform, and when the cutting tool 5 is chipped. Paying attention to the point that the active power significantly decreases, an upper limit reference waveform obtained by multiplying the initial waveform by a predetermined number (for example, 1.4 times) on the increasing side and a predetermined multiple (for example, 0 .7 times) and a lower limit reference waveform.
【００１３】パターン認識形出力監視装置１２は、基準
有効電力波形設定後に行われるワーク１ごとの加工時
に、モータ電力量検出装置１１によって現に測定された
有効電力波形と上限基準波形および下限基準波形とをパ
ターン認識により比較し、刃具５の寿命を判定し、刃具
５が寿命に達したと判定したとき、パトライト等にてそ
の旨警報する。The pattern recognition type output monitoring device 12 has an active power waveform actually measured by the motor power amount detecting device 11 and an upper limit reference waveform and a lower limit reference waveform at the time of machining each work 1 after setting the reference active power waveform. Is compared by pattern recognition, the life of the cutting tool 5 is determined, and when it is determined that the cutting tool 5 has reached the end of life, an alarm to that effect is given by a patrol light or the like.
【００１４】図７〜図９は、パターン認識形出力監視装
置１２にて刃具５に寿命がきたと判定される場合を例示
している。図７は、円筒度不良の場合を示す。円筒度不
良の場合、図７から、加工期間の中間における波形に上
限基準波形を超える部分があることが分かる。図８は、
面粗さ不良の場合を示す。面粗さ不良の場合、図８か
ら、加工期間の後半における波形に上限基準波形を超え
る部分があることが分かる。図９は、刃具５の欠けによ
る不良の場合を示す。欠けの場合、図９から、加工期間
の途中から波形が下限基準波形を大きく下回ることが分
かる。7 to 9 exemplify a case where the pattern recognition type output monitoring device 12 determines that the cutting tool 5 has reached the end of its life. FIG. 7 shows a case where the cylindricity is poor. In the case of poor cylindricity, it can be seen from FIG. 7 that the waveform in the middle of the processing period has a portion exceeding the upper limit reference waveform. Figure 8
The case of poor surface roughness is shown. In the case of poor surface roughness, it can be seen from FIG. 8 that the waveform in the latter half of the processing period has a portion exceeding the upper limit reference waveform. FIG. 9 shows a case where the cutting tool 5 is defective due to chipping. In the case of chipping, it can be seen from FIG. 9 that the waveform greatly falls below the lower limit reference waveform during the processing period.
【００１５】以上説明したように、本実施形態に係る刃
具寿命診断装置１０は、モータ８より駆動力を得てワー
ク１を加工する刃具５の寿命を診断する刃具寿命診断装
置であり、刃具５によるワーク加工中のモータ８の有効
電力波形を測定するモータ電力量検出装置１１と、モー
タ電力量検出装置１１により測定された新品刃具５によ
るワーク加工中のモータ有効電力波形を初期波形として
取り込み、初期波形に基づいて、当該刃具５の寿命を示
す基準有効電力波形を設定するとともに、基準有効電力
波形設定後、モータ電力量検出装置１１により測定され
た有効電力波形と基準有効電力波形とをパターン認識に
より比較し当該刃具５の寿命を判定するパターン認識形
出力監視装置１２とを備える。このため、本実施形態に
よると、刃具５の欠けの他、刃具５の劣化等に基づく円
筒度および面粗さの品質異常も検出可能となり、刃具５
を交換すべきタイミングを正確に把握でき、刃具費の低
減と加工品質維持の両立を図ることができるようにな
る。As described above, the cutting tool life diagnosing device 10 according to the present embodiment is a cutting tool life diagnosing device for diagnosing the life of the cutting tool 5 for processing the work 1 by obtaining the driving force from the motor 8. A motor power amount detecting device 11 for measuring the active power waveform of the motor 8 during machining of the workpiece, and a motor active power waveform measured by the motor power amount detecting device 11 during machining of the workpiece by the new blade 5 are taken in as an initial waveform, Based on the initial waveform, a reference active power waveform indicating the life of the cutting tool 5 is set, and after setting the reference active power waveform, the active power waveform measured by the motor power detection device 11 and the reference active power waveform are patterned. The pattern recognition type output monitoring device 12 is provided to judge the life of the cutting tool 5 by comparing by recognition. Therefore, according to the present embodiment, in addition to chipping of the cutting tool 5, abnormalities in cylindricity and surface roughness due to deterioration of the cutting tool 5 and the like can be detected.
It is possible to accurately grasp the timing of exchanging the tool, and it is possible to reduce the cost of the cutting tool and maintain the processing quality.
【００１６】また、パターン認識形出力監視装置１２が
当該刃具５に寿命がきたと判定したとき、その旨を警報
するようにしたため、速やかに加工停止、刃具交換など
適切な処置をとることが可能となり、大量の不良品の発
生につながる事態に対して早期の対応をすることができ
るようになる。Further, when the pattern recognition type output monitoring device 12 determines that the cutting tool 5 has reached the end of its life, an alarm is issued to that effect, so that appropriate processing such as machining stop and cutting tool replacement can be taken promptly. As a result, it becomes possible to promptly deal with the situation that leads to the production of a large number of defective products.
【００１７】[0017]
【発明の効果】本発明の刃具寿命診断装置によると、刃
具の欠けの他、刃具の劣化等に基づく円筒度および面粗
さの品質異常も検出可能となり、刃具を交換すべきタイ
ミングを正確に把握でき、刃具費の低減と加工品質維持
の両立を図ることができるようになる。According to the cutting tool life diagnosing device of the present invention, in addition to chipping of the cutting tool, abnormalities in cylindricity and surface roughness due to deterioration of the cutting tool can be detected, and the timing for exchanging the cutting tool can be accurately determined. It is possible to grasp the information, and it is possible to reduce the cost of cutting tools and maintain the processing quality.
【図１】本発明の一実施形態に係る刃具寿命診断装置が
適用された単軸刃具診断システムの構成図である。FIG. 1 is a configuration diagram of a single-axis cutting tool diagnostic system to which a cutting tool life diagnosing device according to an embodiment of the present invention is applied.
【図２】単軸刃具診断システムが適用されるスリーブ加
工ラインを示す図である。FIG. 2 is a diagram showing a sleeve processing line to which a single-axis cutting tool diagnostic system is applied.
【図３】ワークとしてのスリーブが組み込まれた油圧制
御ソレノイドバルブの構成図である。FIG. 3 is a configuration diagram of a hydraulic control solenoid valve in which a sleeve as a work is incorporated.
【図４】初期波形の説明図である。FIG. 4 is an explanatory diagram of an initial waveform.
【図５】有効電力波形の相似的変化および特異的変化に
ついての説明図である。FIG. 5 is an explanatory diagram of similar changes and specific changes of the active power waveform.
【図６】基準有効電力波形の説明図である。FIG. 6 is an explanatory diagram of a reference active power waveform.
【図７】円筒度不良の判定例の説明図である。FIG. 7 is an explanatory diagram of a determination example of defective cylindricity.
【図８】面粗さ不良の判定例の説明図である。FIG. 8 is an explanatory diagram of an example of determination of surface roughness defect.
【図９】刃具の欠けによる不良の判定例の説明図であ
る。FIG. 9 is an explanatory diagram of an example of determining a defect due to chipping of a cutting tool.
１ ワーク ５ 刃具 ８ モータ １０ 刃具寿命診断装置 １１ モータ電力量検出装置 １２ パターン認識形出力監視装置 1 work 5 cutting tools 8 motor 10 Cutting tool life diagnosis device 11 Motor power detection device 12 Pattern recognition type output monitor
Claims (2)
る刃具の寿命を診断する刃具寿命診断装置であって、 刃具によるワーク加工中のモータの有効電力波形を測定
するモータ電力量検出装置と、 前記モータ電力量検出装置により測定された新品刃具に
よるワーク加工中のモータ有効電力波形を初期波形とし
て取り込み、該初期波形に基づいて、当該刃具の寿命を
示す基準有効電力波形を設定するとともに、基準有効電
力波形設定後、前記モータ電力量検出装置により測定さ
れた有効電力波形と前記設定された基準有効電力波形と
をパターン認識により比較し当該刃具の寿命を判定する
パターン認識形出力監視装置とを備えることを特徴とす
る刃具寿命診断装置。1. A tool life diagnosing device for diagnosing the life of a cutting tool for machining a work by obtaining a driving force from a motor, the motor power amount detecting device for measuring an active power waveform of a motor during machining of a work by the cutting tool. The motor active power waveform measured by the motor power detection device by a new cutting tool during processing of a motor is taken as an initial waveform, and based on the initial waveform, a reference active power waveform indicating the life of the cutting tool is set, After setting the reference active power waveform, a pattern recognition type output monitoring device that determines the life of the cutting tool by comparing the active power waveform measured by the motor power detection device and the set reference active power waveform by pattern recognition. A blade tool life diagnosing device comprising:
該刃具に寿命がきたと判定したとき、その旨を警報する
ことを特徴とする請求項１記載の刃具寿命診断装置。2. The cutting tool life diagnosing device according to claim 1, wherein when the pattern recognition type output monitoring device determines that the cutting tool has reached the end of its life, it issues an alarm to that effect.
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| JP2002048542A JP2003245846A (en) | 2002-02-25 | 2002-02-25 | Cutting tool life diagnostic apparatus |
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Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN100506654C (en) * | 2003-09-24 | 2009-07-01 | 利乐拉瓦尔集团及财务有限公司 | Packaging-filling device and packaging material cutting device |
| WO2013088841A1 (en) * | 2011-12-13 | 2013-06-20 | オムロン株式会社 | Diagnostic apparatus and diagnostic method |
| JP2013124934A (en) * | 2011-12-14 | 2013-06-24 | Omron Corp | Evaluation apparatus, evaluation method and evaluation program |
| KR101473580B1 (en) | 2013-08-30 | 2014-12-16 | 서울대학교산학협력단 | method for monitoring of cutting machine |
-
2002
- 2002-02-25 JP JP2002048542A patent/JP2003245846A/en active Pending
Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN100506654C (en) * | 2003-09-24 | 2009-07-01 | 利乐拉瓦尔集团及财务有限公司 | Packaging-filling device and packaging material cutting device |
| WO2013088841A1 (en) * | 2011-12-13 | 2013-06-20 | オムロン株式会社 | Diagnostic apparatus and diagnostic method |
| JP2013124934A (en) * | 2011-12-14 | 2013-06-24 | Omron Corp | Evaluation apparatus, evaluation method and evaluation program |
| KR101473580B1 (en) | 2013-08-30 | 2014-12-16 | 서울대학교산학협력단 | method for monitoring of cutting machine |
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