JP6526583B2 - Cutting machine monitoring device - Google Patents

Description

  The present invention relates to the field of cutting machining such as drills and taps.

  In the field of metal cutting such as drills and taps, the state of a cutting tool such as a drill greatly affects the processing quality. For example, Patent Documents 1 and 2 are known as techniques for monitoring the state of a cutting edge tool and giving an alarm in the case of abnormality.

  In the technology of Patent Document 1, an abnormality of the operating unit is detected based on the rate of change of the power supplied to the motor that drives the operating unit. The abnormality of the actuating portion is, for example, the occurrence of an abnormality such as a defect in the cutting tool K or the like. Further, Patent Document 1 discloses that when the cutting tool K is broken, it is in a no-load state, and the power supplied to the motor M is abnormally reduced.

  According to the technology of Patent Document 2, when the current flowing through the motor, ie, the load current value is equal to or more than the threshold value, the display device displays that an abnormality has occurred in the equipment, and whether the number of times of processing is equal to or more than the set number Determine. If the number of times the tool has been machined is equal to or greater than the set number, it is determined that the tool has reached the end of life, and a display for instructing the operator to perform tool replacement is performed.

  When the cutting tool is repeatedly cut, the cutting edge deteriorates and the processing quality can not be maintained. For this reason, the tool maker usually sets the recommended number of cutting times for each cutting edge tool, and the user changes the tool to a new one when it reaches the recommended number of cutting times, or regrind the cutting edge. use. Failure to replace or regrind with a new tool will result in the loss of processing quality and the production of defective products. In addition, a "cutting-edge tool" shall also be described as a "cutting-tool" or only a "tool."

The following techniques are known to prevent the production of such defective products.
(1) Registration / storage means of cutting frequency (recommended cutting frequency) recommended by tool manufacturer (2) Counting frequency of cutting frequency for each tool (3) Comparison of cutting frequency (count number) of each tool with recommended cutting frequency Means (4) Means for outputting an alarm for prompting tool exchange when the number of cutting times exceeds the recommended number of cutting times (5) Means for notifying that tool exchange has been carried out (cutting tool exchange signal output) (6) By means of cutting tool exchange signal Measures to cancel the alarm Count the number of cuts from the first time you start using the tool, and issue an alarm if the number of cuts (count) exceeds the tool manufacturer's recommended value, and the operator will change the tool by the alarm Therefore, the number of cuttings is reduced to the number recommended by the manufacturer or less to protect the processing quality.

Further, the prior art of Patent Document 3 is known.
In the invention of Patent Document 3, after the idle variation in the previous cycle is added to the threshold in the current cycle, the measured value of the electric energy of the motor during the processing operation in the current cycle is compared with the threshold. As a result, even when the electric energy of the motor used for detecting the load abnormality fluctuates in idle when drilling and the like are continuously performed, the load abnormality can be detected with high accuracy. The idle fluctuation is, for example, a fluctuation as shown in FIG. 2 of Patent Document 3, and when there is idle fluctuation, the amount of electric power of the motor is shifted to increase.

Further, for example, the prior art described in Patent Document 4 is known.
The invention of Patent Document 4 provides a method capable of automatically calculating the alarm setting value correctly even when the cutting tool is replaced. Therefore, based on the feature of the active power waveform data of each cutting tool of the machine tool 11, a warning set value calculation method is prepared in advance for each cutting tool. Then, the diagnostic device 12 connected to the machine tool collects active power waveform data such as power values from the machine tool, and adds, to the active power waveform data, blade information indicating which blade is used at the time of collection. By selecting the alarm setting value calculation method based on the cutting tool information, the alarm setting value is correctly calculated even if the cutting tool is replaced.

JP 2000-152689 A Japanese Patent Application Laid-Open No. 10-6170 JP, 2009-78338, A JP, 2006-82154, A

  As described above, in the conventional system, for example, when the number of times of cutting (count number) reaches the recommended number of times of cutting, an alarm to urge tool change is output and a signal notifying that tool change has been performed ( The alarm is canceled by the blade replacement signal).

  In the conventional system, when a worker or the like operates a predetermined switch, the blade tool replacement signal is output. That is, when the above-mentioned alarm occurs, a worker etc. usually canceled the alarm by performing the tool exchange operation and operating the above-mentioned predetermined switch. The alarm may be canceled and the number of times of cutting (count number) may be reset to zero in response to the blade replacement signal.

  However, tool replacement operations often take time, and site workers who wish to proceed with processing operations on schedule perform the above switch operation without performing tool replacement operations and send a blade replacement signal to clear the alarm. Unauthorized work has often been seen, letting the machine continue processing as it is.

  Alternatively, in a system provided with a monitoring device for monitoring a machine that performs the cutting, a mode in which the blade changing signal is used to distinguish whether the blade is abnormal (broken blade) or immediately after replacing the blade. There was also. That is, for example, when using the power value in the "cutting area" disclosed in Patent Document 4 above, it is known that the power value becomes extremely small, for example, when the blade is broken, because the object is not cut. There is. In addition, if the cutter is used continuously, it will deteriorate, and the power value in the "cutting area" will gradually increase accordingly. That is, immediately after replacing the cutting tool, the power value in the “cutting area” is small, and then this power value gradually increases. This is because the cutting edge is sharp when the tool is new, the power consumption required for cutting is low, the cutting edge wears when cutting is repeated, and the power consumption required for cutting is large. When the predetermined number of times is reached and the tool is replaced, the cutting edge recovers from a worn state to a sharp state, and the power value necessary for cutting returns to a small value again.

  As described above, the power value in the “cutting area” decreases in both the case where the cutting tool is abnormal (broken blade) and the case where the cutting tool is just replaced. Furthermore, comparing the two, the power value of the blade breakage is smaller. However, even if it is intended to distinguish between the two using some kind of threshold value, for example, there may be fluctuations in the power value such as idle fluctuation, so that it can not always be distinguished accurately.

  From the above-mentioned circumstances, in order to distinguish whether it is an abnormality (blade breakage) of the cutting tool or immediately after replacement of the cutting tool, it is considered to use the above-mentioned cutting tool replacement signal. That is, when it is determined that "power value is small" using a threshold etc., if there is a blade exchange signal at that time, it is determined as "immediately after blade replacement", and if there is no blade exchange signal, "blade" It is determined that it is broken. Such a technology is referred to as a base technology.

Here, FIG. 7 shows an example of the system configuration of the above-mentioned prior art.
In FIG. 7, first, a monitoring target or the like by the illustrated cutting machine monitoring device 50 according to the above-described technology will be described. The monitoring target is a machine tool 61, which is a machine having a tool (cutting tool) that performs cutting, and shows the case where the cutting tool is a drill here. A motor 62 for driving the machine tool 61 (rotating a drill) is also provided. Furthermore, a measuring device (not shown) for detecting the power consumption by the motor 62 is provided. The power consumption value measured by the measuring device is input to the cutting machine monitoring device 50.

  The machine tool 61 (and the motor 62) performs cutting (piercing) of a processing target (not shown). Further, a cutting number counting device 64 for counting the number of cutting operations (for example, the number of processing target objects subjected to cutting) and the cutting tool replacement alarm device 65 are further provided. The blade tool replacement alarm device 65 issues an alarm when the count number of the cutting number counting device 64 reaches the preset recommended number of cutting times. The method of emitting an alarm may be various, such as light and sound, and flashing of an alarm lamp, display of an alarm message, a buzzer, a siren, etc. can be considered, but the present invention is not limited to this example.

  And, a switch 63 is provided. When a worker or the like depresses the switch 63, the blade tool replacement signal is output (ON), whereby the warning by the blade tool replacement alarm device 65 is canceled and the count number of the cutting number counting device 64 is '0'. Reset to '. The cutting tool change signal is also input to the cutting machine monitoring device 50. This is an example and is not limited to this example. For example, the cutting tool replacement signal may be input only to the cutting machine monitoring device 50, and may not be used for alarm release or count number reset. In addition, the cutting tool replacement alarm device 65 may be omitted. In this case, a worker etc., for example, refers to the count number of the number-of-cuts counting device 64 to determine the blade replacement time by itself, and manually resets the count number when the blade is replaced.

  As described above, the measurement value of the power consumption of the motor 62 is input to the cutting machine monitoring device 50 as needed, and the blade replacement signal is input by pressing the switch 63. The measured value of the power consumption is accumulated and stored, for example, in the data storage unit 51.

  The illustrated data processing unit 52 of the cutting machine monitoring device 50 determines the presence or absence of abnormality (blade breakage) of the cutting tool based on these inputs. In that case, it can distinguish and distinguish from the case immediately after exchange of a cutting tool. First, based on the measurement value of the power consumption of the motor 62, it is determined whether or not it is in the normal state.

  Then, when it is determined that the state is not normal, it is determined whether the blade is abnormal (broken blade) or immediately after replacement of the blade. As described above, if there is the blade replacement signal, it is determined that the blade has just been replaced. Even if it is determined that the cutting tool is not in the normal state, if it is immediately after replacing the cutting tool, it may be regarded as the normal state.

  In this way, the cutting machine monitoring device 50 of the above-mentioned prior art can determine the presence / absence of abnormality (broken blade) of the cutting tool while distinguishing it from the case where it is not actually abnormal (immediately after replacement of the cutting tool). it can.

However, in the above-described base technology, there may be cases where the correct determination result can not be obtained when there is the above-mentioned improper work.
Such a prerequisite technology is an example, but in any case, the switch 63 can be operated in spite of the fact that the illegal operation of the switch 63 (illegal operation related to the tool exchange), that is, the worker etc. It is desirable to be able to determine that the blade replacement signal is being output by performing an unauthorized operation of pressing.

  An object of the present invention is to provide a cutting machine monitoring device and the like that can detect an incorrect operation related to tool replacement.

The cutting machine monitoring device of the present invention has the following means.
Power value input means for inputting a power consumption value of a driving device for driving a tool for cutting an arbitrary processing object;
Condition management means for setting a tool replacement look-alike state when there is an input of a blade replacement signal which is generated when a predetermined switch operation is performed and which is a signal notifying that tool replacement has been performed;
· In the case of the tool replacement sighting state, using the previous value and the current value which are values before and after the tool replacement sighting state becomes the predetermined value related to the power consumption value, the previous value is changed to the current value A tool change determining unit that determines whether the tool change has been performed or not performed based on the variation;
A warning means for setting a warning state in which a tool change not yet performed warning is issued when it is determined that the tool change is not performed .
Here, the predetermined value related to the power consumption value is an integrated power amount which is an integrated value of the power consumption value in a predetermined period, or a processing power value which is a maximum value or an average value of the power consumption values in the predetermined period. It is.

  According to the cutting machine monitoring device and the like of the present invention, it is possible to detect an unauthorized operation related to tool replacement.

It is a functional block diagram of the cutting machine monitoring apparatus of this example. It is a flowchart figure showing a part of processing of a cutting machine monitoring device. (A)-(c) is an example of electric power value data inputted into a cutting machine monitoring device, and integrated electric energy. (A) and (b) are specific examples of the integrated power amount S, its variation amount ΔS, and each threshold value. (A), (b) is a figure for demonstrating the case where tool exchange is implemented. (A), (b) is a figure for demonstrating the case where tool exchange is not implemented. It is a functional block diagram of the cutting machine monitoring device of a prior art.

Hereinafter, embodiments of the present invention will be described with reference to the drawings.
FIG. 1 is a functional configuration diagram of a cutting machine monitoring device 10 of the present example.
Moreover, the monitoring object of the cutting machine monitoring apparatus 10 of this example, etc. are shown in FIG. The monitoring target or the like may be the same as the above-described base technology, and the configuration shown in FIG. 6 is shown here with the same reference numerals. That is, the machine tool 61, the motor 62, the switch 63, the number-of-cuttings counting device 64, and the blade tool replacement warning device 65 are shown. However, the number-of-cuttings counting device 64 and the cutting tool replacement warning device 65 are not necessarily required (may not be necessary).

  Since each of these configurations has already been described, the machine tool 61 is a cutting machine provided with a cutting tool such as the cutting tool (cutting tool), if briefly described here. In addition, a cutting edge tool (cutting blade) may be simply described as a "tool". The cutting tool is, for example, a drill or the like, and the motor 62 rotates the drill or the like, thereby cutting (piercing or the like) a processing target (not shown).

  The cutting number counting device 64 counts the number of cutting operations, and the cutting tool replacement alarm device 65 issues an alarm when the counted number reaches the recommended number of cutting times. The alarm is canceled and the number-of-times-of-cuts count value is reset to zero by the blade changing signal output by the operator or the like pressing the switch 63. As described above, this is an example, and the present invention is not limited to this example. As described above, the blade replacement signal is a signal notifying that the tool replacement has been performed (a signal notifying that the blade replacement has been completed).

  When an alarm is given by the blade tool replacement alarm device 65, usually, a worker etc. replace the blade tool (drill etc.) of the machine tool 61 and then depress the switch 63, but as described above, replace the drill etc. There is a case where a fraudulent act of pressing the switch 63 although not being performed may be performed. The cutting machine monitoring device 10 of this example can cope with such fraudulent acts.

  First, the input to the cutting machine monitoring device 10 is the above-mentioned cutting tool replacement signal and the power measurement value of the motor 62, as in the cutting machine monitoring device 50 of the above-mentioned prior art. Although not shown in the drawings, a measuring device (not shown) for measuring the power consumption of the motor 62 is provided as in the above-described base technology.

  Similar to the above-described base technology, the cutter replacement alarm device 65 outputs an alarm for prompting tool replacement when the count value of the number of times of driving (the number of cutting times) of the machine tool 61 reaches the recommended number of cutting times set in advance. After that, when there is an output (ON signal) of the cutting tool replacement signal, the alarm is canceled and the number of times of cutting is reset to '0'.

  When the worker depresses the predetermined switch 63, a blade replacement signal is output. The cutting tool replacement signal is used for alarm release and the like as described above, but is also input to the cutting machine monitoring device 10.

  When the cutting tool monitoring signal is input, the cutting machine monitoring device 10 turns on a switching signal memory (such as a flag) (not shown). This flag ON means that it is in a tool change look-alike state. The tool change sight state means that tool change should be performed if there is no incorrect operation. From this, in the specific example to be described later, the determination in step S15 to be described later is performed in the tool replacement viewing state, and it is determined whether the tool replacement is actually performed or not performed (illegal operation) Do. Details will be described later.

  In addition, the cutting machine monitoring device 10 holds the previous value of the predetermined value (the integrated power amount S or the like described later) obtained from the input power measurement value of the motor 62. Here, the integrated power amount S described later will be described as an example. The cutting machine monitoring apparatus 10 receives the electric power measurement value of the motor 62 along with it every time the cutting operation is performed on an arbitrary object to be processed, thereby obtaining the integrated electric power amount S described later. Then, the integrated power amount S (current value) obtained this time is held as a new previous value. Then, a new current value which is the integrated power amount S obtained along with the cutting operation on the next processing object, the previous value held as described above, a threshold set in advance, the exchange signal memory (flag Based on etc.), it is judged whether there is an abnormality of the cutting tool (cutting blade etc.) or replacement of the cutting tool. In this way, it is possible to detect fraud associated with tool replacement. Moreover, it is possible to reliably determine whether the tool is abnormal (such as a broken blade) or whether it is a tool change. An example of this process is shown in FIG. FIG. 2 will be described later.

Here, various functions of the cutting machine monitoring device 10 of FIG. 1 and various data to be generated / held will be described.
The cutting machine monitoring device 10 has a data processing unit 11 and a data storage unit 16. The data processing unit 11 includes various functional units such as a change amount threshold registration processing unit 12, a measurement processing unit 13, a change amount calculation processing unit 14, and a determination processing unit 15. In addition, this is only an example and is not limited to this example. For example, the cutting machine monitoring device 10 may have various functional units (not shown) described later.

  The cutting machine monitoring device 10 is realized on a computer device having an arithmetic processor such as a CPU / MPU (not shown) and a storage unit such as a memory (not shown). A predetermined application program is stored in advance in the storage unit. When the arithmetic processor executes this application program, the processing of various functional units in FIG. 1 and the processing of various functional units (not shown) are realized.

  Further, the cutting machine monitoring device 10 may further include an alarm unit 17 and an operation panel 18 as illustrated. The alarm unit 17 may be, for example, a buzzer, a lamp, a siren, a display, or any other device that can notify the user of an alarm in any form.

  The control panel 18 is, for example, a keyboard or the like. However, the present invention is not limited to this example, and any configuration may be used as long as a user (human) can input desired data. Here, in particular, the user operates the operation panel 18 to set and input a desired change amount threshold value. The change amount threshold registration processing unit 12 stores the set “change amount threshold” in the data storage unit 16. In addition, although the threshold value A, the threshold value B, the threshold value C etc. which are mentioned later are examples of a "change amount threshold value", it is not restricted to this example.

  The measurement processing unit 13 inputs, for example, a power consumption value at the time of cutting of a drive device that drives a tool for cutting an arbitrary processing target. For example, the power measurement value of the motor 62 is input. Then, for example, an integrated power amount S to be described later is obtained from the input power measurement value of the motor 62.

  The cutting machine monitoring device 10 further includes a state management unit (not shown) for setting a tool replacement look-alike state when there is an input of a blade replacement signal generated when, for example, a predetermined switch operation is performed. It may be.

  The change amount calculation processing unit 14 obtains a value indicating a change from the previous value to the current value of the predetermined value related to the power consumption value. Although this calculates | requires integral electric power change amount (DELTA) S mentioned later from the integral electric energy S etc. which are mentioned later, for example, it does not restrict to this example. Further, for example, the predetermined value related to the power consumption value is the integrated power amount S or the like which is an integrated value of the power consumption value during a predetermined period (for example, a cutting period described later).

  The judgment processing unit 15 actually carries out the tool exchange based on the change from the previous value to the current value of the predetermined value (integrated power amount S) related to the power consumption value in the tool exchange sightline state. Determine if it has been done or not. In other words, for example, it is determined whether or not the switch 63 has been tampered with. For example, a threshold for tool replacement determination corresponding to the difference between the previous value and the current value is set in advance, and the determination processing unit 15 actually performs tool replacement based on the difference and the threshold. Determine whether it has been done or not.

  The determination processing unit 15 performs predetermined determination including determination of unauthorized operation of the switch 63 based on, for example, the integrated power change amount ΔS, the change amount threshold, the flag, and the like. Furthermore, if it is determined that the switch 63 has been tampered with, the alarm unit 17 issues a warning (a warning that the tool has not been changed). This warning is then continued until it is determined that the cutting tool has been replaced. The details will be described later with reference to FIG.

  The cutting machine monitoring device 10 may further include, for example, an abnormality determination unit (not shown) that determines whether the state is normal or abnormal. The abnormality determination unit (not shown) determines whether the normal state is or not based on a predetermined value (integrated power amount S) or the like related to the power consumption value, for example, when it is not in the tool replacement sighting state.

FIG. 2 is a flow chart showing a part of the processing of the cutting machine monitoring device 10.
The cutting machine monitoring device 10 executes, for example, the process of FIG. 2 each time a cutting operation of a processing target (not shown) is performed. When the process of FIG. 2 is executed, it is assumed that the integrated processing amount S (current value) at this time is obtained by the measurement processing unit 13.

  Here, the cutting machine monitoring device 10 is based on the previous value and the current value of the integrated power amount S immediately after the start of the process of FIG. 2 (or before making the determination in the process of step S11 or step S15). Integrated power change amount ΔS (= current value−previous value).

Although not shown, for example, processing of holding the current value as a new previous value is also performed at the end of the processing of FIG.
Here, the integrated power amount S will be described with reference to FIG.

  FIGS. 3A to 3C are specific examples of power value data (power measurement value of the motor 62) input to the cutting machine monitoring device 10. FIG. The illustrated power value data is time series data from the start to the end of cutting of an arbitrary workpiece, and the integrated power amount S can be obtained from this time series data, for example. About such power value data (time-series data), for example, Patent Document 3 and Patent Document 4 have substantially the same disclosure.

First, the illustrated power value data itself will be described using the typical example shown in FIG.
When cutting is started, the drill starts rotating from a stop state. The power value required for such start-up becomes very large as illustrated. Thereafter, after the drill reaches a predetermined number of revolutions, the machine is in an idling state (idle state) until the drill starts cutting the workpiece. In the idling state, as shown, the power value is very small.

  Then, when the cutting is started, the power value increases as shown, and when the cutting is ended, the power value becomes the same value as in the idle state. Such a period from the start of cutting to the end is referred to as a cutting period.

  The integrated power amount S is, for example, an integrated value of power values in the cutting period, that is, the area S of a region indicated by oblique lines in the drawing. The method of determining the area S is well known (such as integration) and will not be described.

  Here, for example, the maximum value or the average value of the power values in this cutting period is referred to as a processing power value P. The figure shows an example where the processing power value P is the maximum value, that is, the case where it is the maximum value among the power value (instantaneous value) group in the cutting period, and this example is used in the following description. Do.

Further, FIG. 3B shows various specific examples of the integrated power amount.
First, it is assumed that the integrated power amount S shown in FIG. 3 (a) is the previous integrated power amount S1 shown in FIG. 3 (b). This integrated power amount S1 is shown by the integrated value (area) of the power value in the cutting period of a solid line in FIG. 3 (b). Then, three examples shown in the drawings are shown as an example of the current integrated power amount. This shows a normal example by the integrated value (area) of the power value in the cutting period indicated by the alternate long and short dash line, an example in which the cutting tool is replaced by the integrated value (area) of the power value in the cutting period indicated by the dotted line An example where there was an indication is shown by the integrated amount (area) of the electric power value in the cutting period of a two-dot chain line.

  Then, the previous integrated power amount S shown by the solid line data is S1, the current integrated power amount S not replacing the cutting tool shown by the alternate long and short dash line data is S2, and the current integrated power amount S immediately after changing the cutting tool shown by dotted line data is S3, The integrated power amount S after blade breakage shown by dot-and-dash line data is S4. Therefore, the change amount ΔS (= current value−previous value) of the integrated power amount is ΔS2 = S2-S1 when the blade is not replaced, and ΔS3 = S3-S1 when the blade is replaced. In this case, ΔS4 = S4-S1.

  When the blade is not replaced, the integrated power amount S does not change much from the previous value (the power value in each time tends to increase gradually). On the other hand, in the case of blade replacement or blade breakage, the current value is very small compared to the previous value. Thereby, the integrated power change amount ΔS becomes a relatively small value (slightly increased or slightly decreased) in the normal case, but becomes a relatively large negative value in the case of blade replacement or blade breakage. Further, in comparison between blade replacement and blade breakage, the integrated power amount S is smaller in the case of blade breakage than in the blade replacement. Therefore, the integrated power change amount ΔS becomes a larger negative value in the case of blade breakage than in the case of blade replacement. Therefore, it can be said that the relationship between the respective integrated power change amounts ΔS becomes a relationship of ΔS2> ΔS3> ΔS4.

  The above-described integrated power amount S and the integrated power change amount ΔS are substantially the same as the processing power value P and the change amount ΔP. In the present embodiment, processing using the change amount of the integrated power amount S (area S) is performed, and thresholds (a plurality of threshold values) on both the increase side and the decrease side are provided. This will be described below with reference to FIG.

  In each of FIGS. 4A and 4B, the vertical axis is the integrated power amount S, and as a specific example, the integrated power amounts S1, S2, and S3 in the drawing are shown. The integrated power amount S1 is a previous value, and the integrated power amounts S2 and S3 are current values.

  As shown in FIG. 4A, the current value S2 of the integrated power amount is a current value when the blade is not replaced, and is a value almost unchanged from the previous value S1 of the integrated power amount. Therefore, the integrated power change amount ΔS becomes a relatively small value (slightly increased or slightly decreased) as shown in the drawing. As the tendency of the integrated electric energy each time, it becomes a gradual increase tendency (not shown).

  Further, as shown in FIG. 4B, the current value S3 of the integrated power amount is a current value when the cutting tool is replaced, and is greatly reduced from the integrated power amount S1 which is the previous value. Therefore, the integrated power change amount ΔS becomes a relatively large negative value as shown in the drawing.

Further, although not shown in the figure, when there is a broken blade, the current value becomes a value smaller than the integrated power amount S3.
Here, in the present embodiment, it is assumed that three types of thresholds (threshold A, threshold B, threshold C) shown in the figure are used. As illustrated, the threshold A is a positive value, and the threshold B and the threshold C are negative values.

The threshold B is a threshold corresponding to a broken blade, and the abnormality determination unit determines that there is a broken blade when the integrated power change amount ΔS is less than the threshold B (ΔS <B). Do.
Further, the threshold C is a threshold corresponding to a blade replacement, and when the integrated power change amount ΔS is less than the threshold C (ΔS <C), the determination processing unit has a blade replacement It is determined that As described above, since the integrated power amount S3 shown in FIG. 4B is a value when the cutting tool is replaced, the integrated power change amount ΔS in this case is less than the threshold C as illustrated. In other words, the integrated power change amount ΔS in this case is a negative value larger than the threshold C as illustrated.

  Here, as described above, when blade breakage occurs, the integrated power amount S becomes a very small value, and the threshold value B is provided accordingly. However, the abnormal state is not limited to the blade breakage but, for example, there is a processing defect such as “biting of chips”. When such a processing failure occurs, the change value abnormality on the increase side occurs. The threshold value corresponding to processing defects such as “chipping of chips” is the threshold value A. As shown in FIG. 4A, the threshold A is a positive value larger than the integrated power change amount ΔS in the illustrated normal state. If the integrated power change amount ΔS is larger than the threshold A (ΔS> A), the abnormality determination unit determines that there is a processing failure such as “biting in of chips”.

In the present embodiment, for example, the process shown in FIG. 2 is performed using the above three types of thresholds (Threshold A, Threshold B, Threshold C).
It returns to the explanation of FIG.

  FIG. 3C shows a specific example of the integrated power amount in the normal case. Here, two types are shown, which are indicated by thin solid lines and thick solid lines. The direction shown by the integrated value (area) of the power value in the cutting period of a thin solid line is, for example, the integrated power amount in the morning, and the one shown by the integrated value (area) of the power value in the cutting period of the thick solid line is Integrated power amount in

  In the illustrated example, the integrated power amount is generally smaller in the morning than in the evening. However, the present invention is not limited to this example. Conversely, in the morning, a phenomenon may occur in which the integrated power amount is generally larger than in the evening. The reason why such a phenomenon (overall fluctuation of the accumulated power amount) occurs is unknown, but it is a phenomenon actually occurring in the field.

  As described above, even in the normal state, the integrated power amount may fluctuate overall. Therefore, in the case where abnormality determination is made using the threshold value with respect to the integrated power amount S, there is a possibility that erroneous determination may be made due to the influence of fluctuation. However, this variation is a relatively long-term variation such as the morning and the evening as described above, for example, and does not vary in the short time as in the previous and the present. Therefore, the integrated power change amount ΔS is hardly affected by such fluctuation. Therefore, according to the present method, even if the power value data fluctuates, it is possible to correctly determine the presence or absence of an unauthorized operation.

As above, FIG. 3 has been described.
It returns to the explanation of FIG.
As described above, in the present embodiment, the three types of thresholds (threshold A, threshold B, threshold C) related to the integrated power change amount ΔS are arbitrarily set and stored in a memory or the like. Although the values of A, B and C may be determined arbitrarily, in the case of this example, A is a positive value, B and C are negative values, and the relationship of “B <C <A” Set to be

The process of FIG. 2 will be described below.
In the process of FIG. 2, first, it is checked whether the exchange signal memory (flag or the like) is ON (step S13). In other words, it is determined whether or not the tool replacement is in review.

  Then, if the flag is OFF (step S13, NO), it is determined whether the integrated power change amount ΔS is within the normal range (step S11). That is, it is determined whether or not the integrated power change amount ΔS is within the range between the threshold B and the threshold A (within the normal range; B <ΔS <A). The threshold C is a threshold for determining whether or not the blade is replaced, and is not for determining normality / abnormality.

  Then, if the integrated power change amount ΔS is within the above normal range (B <ΔS <A) (step S11, YES), it is determined that the state is normal (step S12), and no particular processing is performed. .

  If the integrated power change amount ΔS is not within the normal range (B <ΔS <A) (step S11, NO), it is determined that an abnormal state is present (step S14). The abnormal state is, for example, a processing defect such as the above-mentioned blade breakage or the above-mentioned "chipping of chips" or the like. If .DELTA.S.ltoreq.B, the blade is broken, and if .DELTA.S.gtoreq.A, it is a processing defect such as "biting of chips".

  Here, as described above, in the normal state and without blade replacement, the current value of the integrated power value S hardly changes from the previous value, so the integrated power change amount ΔS (= current value−previous value) ) Is a very small value. On the other hand, when the blade is broken, the integrated power change amount ΔS has a relatively large negative value. Further, in the case of processing defects such as “chipping”, the integrated power change amount ΔS has a relatively large positive value. For the above-mentioned threshold values A and B, for example, an arbitrary value taking such characteristics into consideration is determined and set in advance by a developer or the like.

On the other hand, if the exchange signal memory (flag or the like) is ON (step S13, YES), in other words, if it is in the tool exchange viewing state, the process takes into account the possibility of the illegal operation in this method. I do. That is, it is determined whether the integrated power change amount ΔS is larger than the threshold C (ΔS> C) (step S15). From the above, it is supposed that ΔS> C in the normal state and without blade replacement.
In addition, when it is in a tool replacement sight state, it can be said that the current value and the previous value in the integrated power change amount ΔS (= current value−previous value) are values before and after the tool replacement sight state. In this case, the integrated power change amount ΔS is obtained from the previous value to the current value which is obtained by using the previous value and the current value which are values before and after the tool replacement look-aside state of the predetermined value related to the power consumption value. It can also be said that it is an example of the value showing the fluctuation of (the difference between the previous value and the current value).

  From this, when ΔS> C is satisfied (step S15, YES), it is considered that tool change has not been actually performed and there has been an unauthorized operation of the switch 63 (step S18). A warning is output (step S19). This outputs a warning from the alarm unit 17 as described above. In this manner, in the present method, it is possible to determine an unauthorized action by a worker or the like, issue a warning, and urge tool replacement.

  On the other hand, if the integrated power change amount ΔS is less than or equal to the threshold C (ΔS ≦ C) (step S15, NO), the tool exchange is actually performed and the switch 63 is improperly operated. It is determined that the tool is in the normal state of tool replacement (step S16). Then, in this case, the exchange signal memory (flag or the like) is reset (turned off). That is, the tool replacement viewing state is released (step S17).

As described in FIG. 4B, in the case immediately after the tool replacement, the integrated power amount S becomes small, and hence the integrated power change amount ΔS becomes a somewhat large negative value, and thus ΔS <C. It becomes.
In step S17, if the warning is generated in step S19, the warning state is canceled. The process of FIG. 2 is repeatedly executed, and in the process of FIG. 2 in the previous time, step S19 was executed to be in the warning state, but in the process of FIG. 2 this time, step S15 is NO. In step S17, the warning state is released. In this case, since the process of step S17 is performed, the determination of step S13 is NO in the process of FIG. 2 next time, and the determination of step S11 is performed. And when blade breakage etc. have occurred, determination of step S11 becomes NO.

  Here, FIG. 5 (b) and FIG. 6 (b) show specific examples of the integrated power amount S at the time of processing for each processing object. The horizontal axis represents the number of machining, which may be considered as the count value T1 of the number-of-times-of-cutting counting device 64. Here, the recommended number of cutting times is 100. Therefore, when the count value T1 becomes 1, 2, 3,..., 99, 100 times, it returns to 1 and is counted again from 1. The vertical axis represents the integrated power amount S, which is the integrated power amount S at the time of cutting of each processing object corresponding to each of the count values.

  And, FIG. 5 (b) shows the case where the blade is replaced when the count value T1 reaches 100 times, and FIG. 6 (b) shows the blade when the count value T1 reaches 100 times. Indicates the case where no action was taken.

  As shown in FIGS. 5 (b) and 6 (b), when the cutting operation is continued and the count value T1 increases, the integrated power amount S at each time tends to gradually increase. In addition, the integrated power change amount ΔS at the time of processing becomes a relatively small value (slight increase or decrease) in the normal state. Therefore, compared with the first integrated power amount S, the 100th integrated power amount S1 is larger to some extent. For this reason, as shown in FIG. 5 (b), when cutting of the finished product (100th unit) is completed and the cutting tool is replaced, the integrated power amount S3 of the first product (first unit) after replacement becomes small. Thus, the integrated power change amount ΔS is a large negative value.

  In the normal processing, the cutting edge wears gradually, and as the tendency of the integrated electric energy every time, it becomes a gradually increasing tendency. In the processing immediately after the tool is replaced, the integrated power amount S sharply drops, and the integrated power amount S thereafter has a gradually increasing tendency.

  On the other hand, as shown in FIG. 6 (b), if the next (101st) cutting operation is performed without performing the tool replacement when the cutting of the final product (100th) is completed, as shown in FIG. The change amount ΔS of the integrated power amount between the first and 101st units is a small value (slight increase or slight decrease) as usual.

  From the above, an appropriate threshold value is set in advance, and every time cutting is performed, the amount of change ΔS from the integrated power at the previous processing to the integrated power at the current processing is calculated and compared with the threshold Thus, it can be determined whether or not the blade has actually been replaced. Since there is a relatively large negative value of the integrated power change amount ΔS as shown in FIG. 5 (b) when the blade is replaced, a threshold (a negative value; here, the threshold C shown in the figure) corresponding thereto is used. If the integrated power change amount ΔS is less than the threshold value C, it may be considered that the blade is replaced.

Further, FIG. 5 (a) shows the process according to the present method when the blade is normally replaced as shown in FIG. 5 (b).
The threshold C is a threshold corresponding to the case of “integrated power change amount ΔS = current value S3−previous value S1”. From this, the threshold C is basically a negative value. Therefore, when the integrated power change amount ΔS is a positive value (in the case of a slight increase) as shown in FIG. 6B described later, the integrated power change amount ΔS is necessarily larger than the threshold C.

  As described above, since the recommended number of times here is 100, when the count value T1 of the number-of-cuttings counting device 64 reaches 100 times, the worker usually performs the tool replacement after switching the switch 63. Manipulate. As a result, the count number of the cutting number counting device 64 is reset to '0', and the cutting tool replacement signal is input to the cutting machine monitoring device 10. From this, the cutting machine monitoring device 10 turns on the exchange signal memory (flag etc.).

  Thereafter, the worker restarts the cutting operation, and when cutting is performed in the next cycle (this time), resistance (cutting resistance) related to cutting becomes low in the case of the blade after replacement, as shown in FIG. As shown in (b), the processing power value P becomes very low, and the integrated power change amount ΔS becomes a relatively large negative value. For this reason, when the cutting machine monitoring device 10 makes a determination based on the integrated power change amount ΔS and the exchange signal memory (flag etc.), it is determined that “tool replacement execution is normal” in step S16.

  Further, FIG. 6 (a) shows the process according to the present method when the blade is not replaced as shown in FIG. 6 (b). However, here, with regard to the processing of “confirm that the value is larger than the threshold C” in the drawing, an example using the threshold C is shown.

  In this case, the count number of the cutting number counting device 64 has reached 100 times, but the operator operates the switch 63 without changing the cutting tool. As a result, the count number of the cutting number counting device 64 is reset to '0', and the cutting tool replacement signal is input to the cutting machine monitoring device 10. Thus, the cutting machine monitoring device 10 turns on the exchange signal memory (flag etc.) as described above. It becomes the same as FIG. 5 (a).

  After that, the worker restarts the cutting operation, and when cutting is performed in the next cycle (this time), in this case, since the blade is not replaced, the integrated power amount S at the time of processing remains high. In the illustrated example, the integrated power amount S is larger than the threshold C. For this reason, if the cutting machine monitoring apparatus 10 makes a determination based on, for example, the integrated power change amount ΔS and the exchange signal memory (flag etc.), it will be determined that “tool exchange not performed” in step S18.

  From the above, the difference between the integrated power amount S at the time of machining at any specified number of times of cutting (100th machine) and the integrated power amount S at the time of processing immediately after replacing the tool thereafter The amount) is measured in advance for each tool, and a developer or the like determines the threshold value corresponding to the amount of drop of the electric energy (corresponding to the integrated power change amount ΔS at the time of processing). . Although an example of this threshold is the above-mentioned threshold C, it is not limited to this example.

  The “threshold C” shown in FIGS. 5 (b) and 6 (b) is a threshold for the change amount ΔS of the integrated power amount S at the time of the processing. The integrated power change amount ΔS between the final product and the first product is previously obtained by empirical / actual measurement, etc., and a value slightly larger than the value of the integrated power change amount ΔS is set as the tool replacement determination threshold C. When the integrated power amount S at the time of processing, which is the current value, is reduced by a threshold C or more in the tool replacement remarking state, it can be determined that the tool replacement is to be performed. If no decrease is observed, it can be determined that tool change has not been performed. In practice, when the tool is not replaced, ΔS takes a relatively small value (slight increase or decrease).

  If the number of cuttings advances and the counter value T1 reaches a predetermined number of times and then the exchange signal memory turns ON, if the next processing is finished in this state, if the tool is actually exchanged, processing The integrated amount of electric power S of the above represents a drop of a threshold C or more from the previous value. When the tool is not replaced and the machining is continued, the change amount ΔS of the integrated electric power S at the machining becomes a relatively small value (slight increase or decrease).

  Usually, it is considered abnormal (blade breakage etc.) when the descent change from the previous value is large, but a large descent change appears when the tool change lookout state (the above replacement signal memory is ON) Is considered to be an implementation of tool change, not an abnormality. Only when the execution of the tool change can be detected, the held tool change review status is released.

As described above, in the tool replacement viewing state, whether or not the tool replacement is performed is determined from the processing power data regardless of the switch operation of the operator, so that the fraud can be detected and fraud can be prevented.
In addition, although the various function parts which the cutting machine monitoring apparatus 10 has as an example shown in FIG. 1, it does not restrict to this example. The cutting machine monitoring device 10 can also be considered to have, for example, various functional units (not shown) described below.

A power value input unit for inputting a power consumption value of a drive device (for example, the motor 62) for driving a tool for cutting an arbitrary processing object;
· A state management unit for setting the above-mentioned tool replacement look-alike state when there is an input of a blade replacement signal generated when there is a predetermined switch operation;
The predetermined switch operation is, for example, a pressing operation of the switch 63.

-In the case of the tool replacement sightline, a tool replacement determination that determines whether the tool replacement has been performed or not based on the change from the previous value to the current value of the predetermined value related to the power consumption value. Department;
· A warning unit for setting a warning state for issuing a warning about non-implementing tool change when it is determined that the above tool replacement has not been performed;
The warning unit cancels the warning state, for example, when the tool replacement determination unit determines that the tool has been replaced in the warning state.

The cutting machine monitoring device 10 can also be considered to further include, for example, various functional units (not shown) described below.
· An abnormality determination unit that determines whether or not the tool is in the normal state based on a predetermined value related to the power consumption value when the tool replacement is not in the inspection state;
For example, when it is determined that the tool replacement has been performed, the tool replacement determination unit cancels the tool replacement viewing state.

The “predetermined value related to the power consumption value” is an integrated value of the power consumption value in a predetermined period, and is, for example, the integrated power amount S. From this, the “variation from the previous value of the predetermined value related to the power consumption value to the current value” is, for example, the integrated power change amount ΔS, but of course, it is not limited to this example as described above.
The predetermined period is, for example, the above-described cutting period.

<Other embodiments>
In the example described above, the integrated power amount S and the change amount ΔS are used, but the present invention is not limited to this example. For example, the processing power value P and the change amount ΔP described in FIG. Value) may be used. In this case, each threshold value for comparison with ΔP is newly set.

Moreover, although the case where a blade was a drill etc. was demonstrated in the example mentioned above, not only this example but a blade may be grinding systems (brush etc.), for example.
Here, when the cutting tool is a polishing system (such as a brush), it exhibits characteristics different from those of a drill or the like. That is, in a polishing system (brush or the like) tool, the power consumption tends to decrease with the deterioration of the tool. This is because when a grinding wheel rotates like grinders or belt grinding, a plurality of sharp cutting edges hit the work and power load is applied at the time of grinding, but when the cutting edges are gradually scraped and become flat (wear When it comes, it is considered that the work slips and the power load decreases. Then, when the tool of the polishing system (brush or the like) is replaced, the power consumption is greatly increased compared to the previous value in order to return to the original value.

  Thus, tools of the grinding system (brush, etc.) exhibit opposite characteristics to a drill, etc. That is, in the case of a polishing system (brush or the like) tool, the integrated power change amount ΔS is normal and becomes a relatively small negative value when there is no blade replacement, and when it is normal and there is blade replacement. It is a relatively large positive value. From this, the threshold value D is arbitrarily set in advance.

  Even in the case of a polishing system (brush or the like) tool, the process of FIG. 2 is basically performed, but the process of step S15 described above does not use the “ΔS> C?” Determination, but “ΔS <D? It shall be judged. Then, when “ΔS <D”, the process proceeds to step S18, and when “ΔS ≧ D”, the process proceeds to step S16.

10 cutting machine monitoring device 11 data processing unit 12 variation threshold registration processing unit 13 measurement processing unit 14 variation calculation processing unit 15 determination processing unit 16 data storage unit 17 alarm unit 18 operation panel 61 machine tool 62 motor 63 switch 64 number of cuts Counting device 65 Cutting tool replacement alarm device

Claims (6)

Power value input means for inputting a power consumption value of a drive device for driving a tool for cutting an arbitrary processing object;
State management means for setting a tool replacement look-alike state when there is an input of a blade replacement signal which is a signal for notifying that tool replacement has been performed, which is generated when a predetermined switch operation is performed,
In the case of the tool replacement sighting state, using the previous value and the current value which are values before and after the tool replacement sighting state of the predetermined value related to the power consumption value, variation from the previous value to the current value A tool replacement determination unit that determines whether the tool replacement has been performed or has not been performed based on
Warning means for setting a warning state for issuing a tool replacement non-execution warning when it is determined that the tool replacement has not been performed;
I have a,
The predetermined value related to the power consumption value is an integrated power amount which is an integrated value of the power consumption values in a predetermined period, or a processing power value which is a maximum value or an average value of the power consumption values in the predetermined period. Cutting machine monitoring device characterized in that.   The cutting machine monitoring device according to claim 1, wherein the warning means cancels the warning state when the tool change determination means determines that the tool has been changed in the warning state.   3. The apparatus according to claim 1, further comprising abnormality determination means for determining whether or not the tool is in a normal state based on a predetermined value related to the power consumption value when the tool replacement sighting state is not in effect. Cutting machine monitoring device. The said predetermined period is a cutting period, The cutting machine monitoring apparatus in any one of the Claims 1-3 characterized by the above-mentioned.   2. The cutting machine monitoring device according to claim 1, wherein the tool replacement determination means releases the tool replacement viewing state when it is determined that the tool replacement has been performed. The fluctuation from the previous value to the current value of the predetermined value related to the power consumption value is the difference between the previous value and the current value,
A threshold for tool replacement determination corresponding to the difference is set in advance,
The tool exchange determination means, on the basis of the said difference and the threshold value, according to any one of claims 1 to 5, replacement of the tool is characterized in that it is determined whether the unexecuted or has been carried out Cutting machine monitoring device.