WO2024111014A1 - Machining load determination system - Google Patents

Abstract

This invention provides a system which increases a detection precision of a difference between simulation and actual machining without limiting a precision of the simulation. This machining load determination system comprises: an actual machining unit which includes a movable unit provided with a tool or a workpiece; a simulation unit which has a virtual space including a virtual tool, a virtual workpiece, and a virtual movable unit; a virtual load acquisition unit which acquires information relating to a virtual load occurring to the virtual movable unit; an actual load acquisition unit which acquires information relating to an actual load occurring to the movable unit; and a load information determination unit which determines whether or not a difference exists between the virtual load information and the actual load information. The simulation unit calculates the virtual load information and comparison position specification data which specifies a position for comparing the virtual load information and the actual load information with each other. The virtual load acquisition unit acquires the virtual load information in association with the comparison position specification data. The actual load acquisition unit acquires the actual load information in association with the comparison position specification data. The load information determination unit compares the virtual load information and the actual load information with each other on the basis of the comparison position specification data.

Description

Machining load judgment system

This disclosure relates to a processing load determination system.

There are industrial machines (e.g., machine tools, electric discharge machines, etc.) that have moving parts on which tools or workpieces are mounted, and process the workpieces by moving the tools and workpieces relative to one another. For such industrial machines, there is a technology that performs a processing simulation using a virtual space that reproduces an environment similar to the environment in which actual processing is performed using a 3D model, and checks for any problems with the operating data (e.g., the processing program).

In this type of technology, various factors can cause unintended differences between the 3D model in the virtual space defined for the simulation and the actual environment. For example, the workpiece may float up during machining in the actual environment, or tool wear compensation may be forgotten to be reflected in the 3D model in the virtual space. In such cases, differences can occur between the results obtained by simulation and the results obtained in actual machining.

In this regard, Patent Document 1 discloses a technology in which an actual machine part and a simulation part are arranged in parallel, the same command is input to the actual machine part and the simulation part, the internal state quantities of the actual machine part and the simulation part are compared, and the internal state quantity comparison value is compared with a preset detection threshold value to detect contact or collision of the moving part with another object. It is believed that this technology makes it possible to detect whether there is a difference between the results obtained by simulation and the results obtained in actual machining. Patent Document 1 also discloses that the calculation formula of the model of the simulation part is simple, resulting in short processing time.

JP 2004-364396 A

In the technology disclosed in Patent Document 1, the simulation of the simulation unit needs to be performed in real time in accordance with the operation of the actual machine. The processing time for a simulation that uses a three-dimensional model as a virtual space is relatively long. Therefore, in the technology disclosed in Patent Document 1, as described above, the calculation formula of the model of the simulation unit is simplified to shorten the processing time in accordance with the operation time of the actual machine.

As described above, the accuracy of the simulation is limited in a real-time simulation of actual machining, and as a result, the difference between the simulation and the actual machining may not be detected correctly.
Therefore, it is desirable to improve the accuracy of detecting the difference between the simulation and the actual machining without limiting the accuracy of the simulation.

The machining load judgment system disclosed herein comprises an actual machining unit having a movable part on which a tool or a workpiece is mounted, and which machines the workpiece by moving the tool and the workpiece relative to each other based on operation data; a simulation unit which performs a machining simulation of the virtual workpiece by moving the virtual tool and the virtual workpiece relative to each other based on the operation data in a virtual space including virtual tools, virtual workpieces, and virtual moving parts corresponding to the tool, the workpiece, and the moving part, respectively; a virtual load acquisition unit which acquires virtual load information occurring on the virtual moving part obtained by the machining simulation by the simulation unit; an actual load acquisition unit which acquires actual load information occurring on the moving part obtained by machining by the actual machining unit; and a load information judgment unit which compares the virtual load information with the actual load information and judges whether there is a difference between these pieces of information. The simulation unit calculates the virtual load information and comparison point identification data that identifies a comparison point between the virtual load information and the actual load information, the virtual load acquisition unit acquires the virtual load information in association with the comparison point identification data, the actual load acquisition unit acquires the actual load information in association with the comparison point identification data, and the load information determination unit compares the virtual load information with the actual load information based on the comparison point identification data.

1 is a diagram showing an overview of an industrial machinery system according to an embodiment of the present invention; 1 is a diagram showing a configuration of a processing load determination system according to an embodiment of the present invention; 11A and 11B are diagrams illustrating an example of virtual load information and comparison portion identification data. 11A and 11B are diagrams illustrating an example of actual load information and comparison location identification data. 11A and 11B are diagrams illustrating a first example of a machining load judgment process performed by the machining load judgment system according to the present embodiment (when there is no difference between an actual machining part and a simulation part); FIG. 11 is a diagram showing Example 1 of a machining load judgment process by the machining load judgment system according to the present embodiment (when there is a difference between an actual machining part and a simulation part: a pattern in which contact is detected only in the simulation part). FIG. 11 is a diagram showing Example 1 of a machining load judgment process by the machining load judgment system according to the present embodiment (when there is a difference between an actual machining part and a simulation part: a pattern in which contact is detected only in the actual machining part). 11 is a diagram showing Example 1 of a machining load judgment process by the machining load judgment system according to the present embodiment (when there is a difference between an actual machining part and a simulation part: a pattern in which a workpiece floats up); FIG. 13A and 13B are diagrams illustrating a second example of a machining load judgment process performed by the machining load judgment system according to the present embodiment (when there is no difference between an actual machining part and a simulation part); FIG. 11 is a diagram showing Example 2 of the machining load judgment process by the machining load judgment system according to the present embodiment (when there is a difference between the actual machining part and the simulation part: a pattern in which contact is detected only in the simulation part). FIG. 11 is a diagram showing Example 2 of the machining load judgment process by the machining load judgment system according to the present embodiment (when there is a difference between the actual machining part and the simulation part: a pattern in which contact is detected only in the actual machining part). 13A and 13B are diagrams illustrating a third example of a machining load judgment process performed by the machining load judgment system according to the present embodiment (when there is no difference between an actual machining part and a simulation part); FIG. 11 is a diagram showing Example 3 of the machining load judgment process by the machining load judgment system according to the present embodiment (when there is a difference between the actual machining part and the simulation part: a pattern in which contact is detected only in the simulation part). FIG. 11 is a diagram showing Example 3 of the machining load judgment process by the machining load judgment system according to the present embodiment (when there is a difference between the actual machining part and the simulation part: a pattern in which contact is detected only in the actual machining part). FIG. 11 is a diagram showing Example 4 of the processing load judgment process by the processing load judgment system according to the present embodiment. FIG. 11 is a diagram showing Example 5 of the processing load judgment process by the processing load judgment system according to the present embodiment.

Below, an example of this embodiment will be described with reference to the attached drawings. Note that the same or equivalent parts in each drawing will be given the same reference numerals.

[Outline of Industrial Machinery System]
First, an overview of the industrial machinery system according to the present embodiment will be described. Fig. 1 is a diagram showing an overview of the industrial machinery system according to the present embodiment. As shown in Fig. 1, the industrial machinery system 100 includes a numerical control device 110, a drive unit 120, and a machine tool (industrial machinery) 130.

The machine tool 130 is the actual machining section described below, and performs removal machining of the workpiece W by moving the tool T and the workpiece W relative to one another based on the operating data. In the following, an M-series (machining center) machine is used as an example of the machine tool, but this embodiment is not limited to this. This embodiment is also applicable to a T-series (lathe) machine tool. In the following, a machine tool is used as an example of the industrial machine, but this embodiment is not limited to this. This embodiment is also applicable to various industrial machines, such as electric discharge machines, in which the tool T and the workpiece W come into contact with each other to machine the workpiece W.

The machine tool 130 includes a motor 132, a tool mounting portion 134, and a table 136. The mounting portion 134 or the table 136 is a movable portion, and a tool T is attached to the mounting portion 134, and a workpiece W is provided on the table 136.

The motor 132 is a motor for feeding the movable part of the mounting part 134 or the table 136, i.e., the tool T or the workpiece W, and may include, for example, multiple motors for X-axis movement, Y-axis movement, and Z-axis movement. The motor 132 is driven by the drive part 120.

The numerical control device 110 generates position commands along the relative movement path of the tool T with respect to the workpiece W in the machine tool 130 based on the machining program.

The driving unit 120 drives the motor 132 in the machine tool 130 based on a position command from the numerical control device 110. The driving unit 120 may include multiple driving units for each motor of the machine tool 130 (e.g., an X-axis motor, a Y-axis motor, and a Z-axis motor). The driving unit 120 is, for example, a servo control unit, and performs drive control of the motor 132 based on the position command and position feedback detected by an encoder provided on the motor 132.

[Processing load judgment system]
2 is a diagram showing the configuration of the machining load judgment system according to the present embodiment. As shown in Fig. 2, the machining load judgment system 10 includes an actual machining unit 12, a simulation unit 14, an actual load acquisition unit 16, a virtual load acquisition unit 18, a storage unit 20, a load information judgment unit 22, an operation control unit 24, a correction unit 26, and a display unit 28.

The actual machining unit 12 is the machine tool 130 described above. As described above, the actual machining unit 12 uses the mounting unit 134 on which the tool T is mounted or the table 136 on which the workpiece W is mounted as a movable unit, and performs machining of the workpiece W by moving the tool T and the workpiece W relative to each other based on the operating data.

The simulation unit 14 may be provided in the above-mentioned numerical control device 110, or may be configured by a computer different from the numerical control device 110. The simulation unit 14 has a virtual space VS including a virtual tool Ts, a virtual workpiece Ws, a virtual mounting part (virtual movable part) 134s, and a table (virtual movable part) 136s, which respectively simulate the tool T, the workpiece W, the mounting part (movable part) 134, and the table (movable part) 136 in the actual machining part 12, as shown in FIG. 4A described later. The simulation unit 14 performs a machining simulation of the virtual workpiece Ws by relatively moving the virtual tool Ts and the virtual workpiece Ws in the virtual space VS based on the operation data. As shown in FIG. 3A, the simulation unit 14 calculates virtual load information generated in the virtual movable parts 134s and 136s, and comparison point identification data that identifies a comparison point between the virtual load information and the actual load information. The details of the virtual load information and the comparison point identification data will be described later.

The actual load acquisition unit 16 is provided in the drive unit (servo control unit) 120 described above. As shown in FIG. 3B, the actual load acquisition unit 16 acquires actual load information generated in the movable parts 134, 136 obtained by processing by the actual processing unit 12. Specifically, the actual load acquisition unit 16 acquires virtual load information in association with comparison location identification data. Details of the actual load information and comparison location identification data will be described later.

The virtual load acquisition unit 18 may be provided in the numerical control device 110 described above, or may be provided in a computer constituting the simulation unit 14, or may be constituted by a computer different from the numerical control device 110 and the simulation unit 14. As shown in FIG. 3A, the virtual load acquisition unit 18 acquires virtual load information generated in the virtual moving parts 134s, 136s obtained by the machining simulation by the simulation unit 14. Specifically, the virtual load acquisition unit 18 acquires the virtual load information in association with the comparison location identification data.

The load information determination unit 22 may be provided in the above-mentioned numerical control device 110, or in the drive unit (servo control unit) 120, or may be configured by a computer different from the numerical control device 110 and the drive unit 120. The load information determination unit 22 compares the virtual load information with the actual load information based on the comparison point identification data, and determines whether or not there is a difference between these pieces of information. In other words, the load information determination unit 22 determines whether or not there is a difference between the load information of the movable parts 134, 136 in the actual machining unit 12 and the load information of the virtual movable parts 134s, 136s in the simulation unit 14.

The operation control unit 24 is provided in the drive unit (servo control unit) 130 described above. When the load information determination unit 22 determines that there is a difference between the virtual load information and the actual load information, the operation control unit 24 performs at least one of the following in the actual machining unit 12: limiting the output for operating the movable units 134, 136 (e.g., torque limiting), performing a retraction operation (retraction) of the movable units 134, 136 that is set in advance in the machining program, or immediately decelerating and stopping the operation of the movable units 134, 136.

The correction unit 26 may be provided in the above-mentioned numerical control device 110, or may be configured by a computer different from the numerical control device 110. When the load information determination unit 22 determines that there is a difference between the virtual load information and the actual load information, the correction unit 26 changes (corrects) the preconditions for the machining simulation in the simulation unit 14, for example, the preconditions related to the virtual tool Ts, the virtual workpiece Ws, and the virtual movable parts 134s and 136s in the operation data.

The above-mentioned simulation unit 14, actual load acquisition unit 16, virtual load acquisition unit 18, load information determination unit 22, operation control unit 24, and correction unit 26 are configured with an arithmetic processor such as a CPU (Central Processing Unit), a DSP (Digital Signal Processor), or an FPGA (Field-Programmable Gate Array). The various functions of the simulation unit 14, actual load acquisition unit 16, virtual load acquisition unit 18, load information determination unit 22, operation control unit 24, and correction unit 26 are realized, for example, by executing a predetermined software (program) stored in the storage unit 20. The various functions of the simulation unit 14, actual load acquisition unit 16, virtual load acquisition unit 18, load information determination unit 22, operation control unit 24, and correction unit 26 may be realized by a combination of hardware and software, or may be realized only by hardware (electronic circuits).

The memory unit 20 is composed of memory such as a ROM (Read Only Memory), HDD (Hard Disk Drive), or SSD (Solid State Drive). The memory unit 20 stores predetermined software (programs) that realize the various functions of the simulation unit 14, the actual load acquisition unit 16, the virtual load acquisition unit 18, the load information determination unit 22, the operation control unit 24, and the correction unit 26. The memory unit 20 also stores the virtual load information and comparison point identification data shown in FIG. 3A acquired by the virtual load acquisition unit 18, and the actual load information and comparison point identification data shown in FIG. 3B acquired by the actual load acquisition unit 16.

The display unit 28 is configured, for example, with a liquid crystal display or an organic EL display. The display unit 28 displays the comparison point identification data for which the load information determination unit 22 has determined that there is a difference between the virtual load information and the actual load information in a different display mode according to the difference. For example, the display unit 28 highlights and displays in a different display mode (for example, color, blinking, etc.) in the program (operation data) the blocks corresponding to the comparison point identification data for which it has been determined that there is a difference between the virtual load information and the actual load information, from blocks with no difference.

Next, several examples of processing load judgment processing by the above-mentioned processing load judgment system 10 will be described with reference to Figs. 4A to 8. Figs. 4A to 4D are diagrams showing Example 1 of processing load judgment processing by the processing load judgment system according to this embodiment, Figs. 5A to 5C are diagrams showing Example 2 of processing load judgment processing by the processing load judgment system according to this embodiment, and Figs. 6A to 6C are diagrams showing Example 3 of processing load judgment processing by the processing load judgment system according to this embodiment. Fig. 7 is a diagram showing Example 4 of processing load judgment processing by the processing load judgment system according to this embodiment, and Fig. 8 is a diagram showing Example 5 of processing load judgment processing by the processing load judgment system according to this embodiment.

[Example 1]
In the first embodiment, the elapsed time (time information) of the program operation is used as the comparison point identification data. Fig. 4A is a diagram showing a case where there is no difference between the actual load information of the moving part in the real machining part and the virtual load information of the virtual moving part in the simulation part, and Fig. 4B is a diagram showing a case where there is a difference between the actual load information of the moving part in the real machining part and the virtual load information of the virtual moving part in the simulation part (a pattern where contact is detected only in the simulation part). Fig. 4C is a diagram showing a case where there is a difference between the actual load information of the moving part in the real machining part and the virtual load information of the virtual moving part in the simulation part (a pattern where contact is detected only in the real machining part), and Fig. 4D is a diagram showing a case where there is a difference between the actual load information of the moving part in the real machining part and the virtual load information of the virtual moving part in the simulation part (a pattern where the workpiece floats up).

(When there is no difference between the actual machining part and the simulation part)
<1-1>
As shown in FIG. 4A, for example, the numerical control device 110 analyzes the machining program, creates time series data Xs(0), Xs(1) to Xs(n) of the machine coordinates Xs(i) of the virtual movable parts 134s, 136s after the time Ts(i) seconds from the start time Ts(0) as operation data for the simulation unit 14, and outputs the data to the simulation unit 14. Also, for example, the numerical control device 110 analyzes the machining program, creates time series data Xr(0), Xr(1) to Xr(n) of the machine coordinates Xr(j) of the movable parts 134, 136 after the time Tr(j) seconds from the start time Tr(0) as operation data for the actual machining unit 12, and outputs the data to the drive unit 120. Here, i and j are any integers from 1 to n. n is an integer of 1 or more. Xs(i) and Xr(j) are q-dimensional arrays, and the mechanical coordinate of the p-th axis of the virtual moving part can be expressed as Xsp(i), and the mechanical coordinate of the p-th axis of the moving part can be expressed as Xrp(j). q is an integer of 1 or more and indicates the number of axes of the machine. p is an arbitrary integer from 1 to q.

In this embodiment, the numerical control device 110 analyzes the machining program and creates time-series data of machine coordinates (operation data). However, this embodiment is not limited to this, and the computer constituting the simulation unit 14 or another computer may analyze the machining program and create time-series data of machine coordinates (operation data).

<1-2>
The simulation unit 14 performs a machining simulation of the virtual workpiece Ws by moving the virtual tool Ts and the virtual workpiece Ws relatively based on the machine coordinates Xs(0) to Xs(n) (operation data) output from the numerical control device 110.

The simulation unit 14 calculates contact information indicating whether or not the virtual tool Ts and the virtual workpiece Ws are in contact with each other as virtual load information generated in the virtual movable parts 134s, 136s at a certain machine coordinate Xs(i) at a certain time Ts(i). For example, the simulation unit 14 sets the contact flag to 0 when the virtual tool Ts is outside the virtual workpiece Ws, and sets the contact flag to 1 when the virtual tool Ts moves from the outside to the inside of the virtual workpiece Ws.

The simulation unit 14 also calculates a certain time Ts(i) as comparison location identification data that identifies a comparison location between the virtual load information and the actual load information. Specifically, the comparison location identification data is data that associates the virtual load information with the actual load information in terms of time series or machining positions. More specifically, the comparison location identification data is data that associates the time Ts(i) at which the virtual tool Ts and the virtual workpiece Ws come into contact with each other in the simulation unit 14 with the time Tr(j) at which the tool T and the workpiece W come into contact with each other in the actual machining unit 12 in a one-to-one manner. That is, the comparison location identification data is data that identifies the time Ts(i) and the time Tr(j) as the comparison location between the virtual load information and the actual load information. This allows the load information determination unit 22 to appropriately compare the virtual load information at the time Ts(i) with the actual load information at the time Tr(j) based on the comparison location identification data.
As described above, the simulation unit 14 may be provided in the numerical control device 110 or may be configured by a computer different from the numerical control device 110.

The numerical control device 110 (virtual load acquisition unit 18) acquires the contact flag 0/1 (virtual load information) in association with the time Ts(i) (comparison point identification data) as shown in FIG. 4A.

The simulation unit 14 performs the above-mentioned machining simulation before the actual machining unit 12 operates based on the operation data, and calculates the virtual load information and the comparison location data in advance. In addition, the virtual load acquisition unit 18 may acquire the virtual load information in advance in association with the comparison location identification data and temporarily store it in the storage unit 20 before the actual machining unit 12 operates based on the operation data.

<1-3>
The driving unit 120 drives the motor 132 and the movable units 134, 136 of the actual machining unit 12 based on the machine coordinates Xr(0) to Xr(n) (operation data) output from the numerical control device 110. As a result, the actual machining unit 12 performs machining of the workpiece W by moving the tool T and the workpiece W relative to each other.

The driving unit 120 (actual load acquisition unit 16) acquires contact information indicating whether or not the tool T and workpiece W are in contact as load information generated in the movable parts 134, 136 at a certain machine coordinate Xr(j) at a certain time Tr(j). For example, the driving unit 120 (actual load acquisition unit 16) monitors the output (command or feedback information) of the motor 132, and when the output of the motor 132 exceeds a certain threshold, it determines that the tool T and workpiece W are in contact, and outputs a contact signal to the numerical control device 110.

The drive unit 120 (actual load acquisition unit 16) acquires the contact signal (actual load information) in association with the time Tr(j) (comparison point identification data).

<1-4>
The numerical control device 110 (load information determination unit 22) compares the contact signal (actual load information) and the contact flag (virtual load information) based on the times Tr(j) and Ts(i) (comparison point identification data) and determines whether there is a difference between these pieces of information. For example, in Fig. 4A, the numerical control device 110 (load information determination unit 22) acquires a contact signal (actual load information) between times Ts(i-1) and Ts(i) based on the times Tr(j) and Ts(i) (comparison point identification data), and since the contact flag (virtual load information) at this time is 1, it determines that there is no difference between these pieces of information.

The load information determination unit 22 makes the above-mentioned determination in real time while the actual machining unit 12 is operating, based on the virtual load information obtained in advance by the simulation unit 14 and the actual load information obtained in real time by the actual machining unit 12.
The load information determining unit 22 may extract and compare only the virtual load information and the actual load information of a specific section in the comparison point specifying data.

If there is no difference between the actual load information and the virtual load information, the numerical control device 110 (operation control unit 24) does not impose any operational restrictions.

As mentioned above, the load information determination unit 22 may be provided in the numerical control device 110, or in the drive unit 120 (servo control unit, amplifier), or may be configured by a computer separate from the numerical control device 110 and the drive unit 120.

When the load information determination unit 22 is provided in the drive unit 120 (servo control unit, amplifier), the load information determination unit 22 calculates the time Tr(j) at which a contact signal is detected in the actual machining unit 12 on the drive unit 120 side, and may determine that there is no difference between the actual load information and the virtual load information if this time Tr(j) and the times Ts(i-1), Ts(i) at which the contact flag changes from 0 to 1 in the simulation unit 14 satisfy the following equation:
Ts(i-1)≦Tr(j)≦Ts(i)

Normally, the period for acquiring the position of the movable part in the actual machining unit is shorter than the simulation period, so the error (delay time) of the time Tr(j) at which the contact signal is detected in the actual machining unit 12 can be ignored. However, if the error (delay time) of the actual machining unit is smaller than the error of the simulation unit 14, the load information determination unit 22 may determine that there is no difference between the actual load information and the virtual load information if there is a time Ts(i) at which the contact flag becomes 1 in the simulation unit 14 between times Tr(j-1) and Tr(j) in the actual machining unit 12.

Furthermore, the load information determination unit 22 may determine that there is no difference between the actual load information and the virtual load information based on a determination based on the contact position as described below, in addition to the determination based on the contact time described above. For example, the load information determination unit 22 may further determine that there is no difference between the actual load information and the virtual load information when the machine coordinate Xr(j) at which a contact signal is detected in the actual machining unit 12 and the machine coordinates Xs(i-1), Xs(i) at which the contact flag changes from 0 to 1 in the simulation unit 14 satisfy the following equation for all axes p in operation between i-1 and i:
|Xrp(j)-Xsp(i)|≦|Xsp(i)-Xsp(i-1)|
This makes it possible to eliminate cases where multiple mistakes result in the same contact time (collision time).

(When there is a difference between the actual machining part and the simulation part) (Pattern in which contact is detected only in the simulation part)
<1-1>
4B, for example, the numerical controller 110, in the same manner as described above, creates time series data Xs(0), Xs(1) to Xs(n) of the machine coordinates Xs(i) of the virtual movable parts 134s, 136s after the time Ts(i) seconds from the start time Ts(0) as operation data for the simulation unit 14. Also, for example, the numerical controller 110, in the same manner as described above, creates time series data Xr(0), Xr(1) to Xr(n) of the machine coordinates Xr(j) of the movable parts 134, 136 after the time Tr(j) seconds from the start time Tr(0) as operation data for the actual machining unit 12.

<1-2>
As described above, the simulation unit 14 performs a machining simulation of the virtual workpiece Ws, and the numerical control device 110 (virtual load acquisition unit 18) acquires the contact flag 0/1 (virtual load information) in association with the time Ts(i) (comparison point identification data), as shown in FIG. 4B.

<1-3>
Similarly to the above, the driving unit 120 and the actual machining unit 12 machine the workpiece W, and the driving unit 120 (actual load acquisition unit 16) acquires a contact signal (actual load information) in association with time Tr(j) (comparison point identification data). For example, in FIG. 4B, the tool T and the workpiece W do not come into contact with each other due to damage to the tool or incorrect installation, and the driving unit 120 (actual load acquisition unit 16) does not acquire a contact signal and does not output the contact signal to the numerical control device 110.

<1-4>
As described above, the numerical controller 110 (load information determination unit 22) compares the contact signal (actual load information) and the contact flag (virtual load information) based on the times Tr(j) and Ts(i) (comparison point identification data) and determines whether or not there is a difference between these pieces of information. For example, in FIG. 4B, the numerical controller 110 (load information determination unit 22) does not acquire a contact signal (actual load information) between times Ts(i-1) and Ts(i), and the contact flag (virtual load information) at this time is 1, so it determines that there is a difference between these pieces of information.

If there is a difference between the actual load information and the virtual load information, the numerical control device 110 (motion control unit 24) decelerates and stops the machine tool 130. The numerical control device 110 (motion control unit 24) may immediately stop the motor output, or may perform a predetermined emergency stop operation. That is, the numerical control device 110 (motion control unit 24) limits the output to operate the movable parts 134, 136 in the actual machining unit 12, performs a preset retraction operation of the movable parts 134, 136, or immediately decelerates and stops the operation of the movable parts 134, 136.

At this time, the machine tool operator can recognize whether the tool T has been attached incorrectly or is damaged by comparing the machine coordinates where contact (interference) was detected in the machining simulation with the machine coordinates where contact (interference) was not detected in the actual machining, which correspond to the machine coordinates where contact (interference) was detected in the actual machining.

(When there is a difference between the actual machining part and the simulation part) (Pattern in which contact is detected only in the actual machining part)
<1-1>
4C, for example, the numerical controller 110, in the same manner as described above, creates time series data Xs(0), Xs(1) to Xs(n) of the machine coordinates Xs(i) of the virtual movable parts 134s, 136s from the start time Ts(0) to the time Ts(i) seconds later as operation data for the simulation unit 14. Also, for example, the numerical controller 110, in the same manner as described above, creates time series data Xr(0), Xr(1) to Xr(n) of the machine coordinates Xr(j) of the movable parts 134, 136 from the start time Tr(0) to the time Tr(j) seconds later as operation data for the actual machining unit 12.

<1-2>
As described above, the simulation unit 14 performs a machining simulation of the virtual workpiece Ws, and the numerical control device 110 (virtual load acquisition unit 18) acquires a contact flag 0/1 (virtual load information) in association with a time Ts(i) (comparison point identification data) as shown in Fig. 4A. For example, in Fig. 4C, at a certain machine coordinate Xs(i) at a certain time Ts(i), the virtual tool Ts does not move from the outside to the inside of the virtual workpiece Ws, and the simulation unit 14 sets the contact flag to 0.

<1-3>
As described above, the drive unit 120 and the actual processing unit 12 process the workpiece W, and the drive unit 120 (actual load acquisition unit 16) acquires a contact signal (actual load information) in association with time Tr(j) (comparison point identification data).

<1-4>
As described above, the numerical control device 110 (load information determination unit 22) compares the contact signal (actual load information) and the contact flag (virtual load information) based on the times Tr(j) and Ts(i) (comparison point identification data) and determines whether or not there is a difference between these pieces of information. For example, in FIG. 4B, the numerical control device 110 (load information determination unit 22) detects that a contact signal (actual load information) has been acquired between times Ts(i-1) and Ts(i) even though the contact flag (virtual load information) has not been set, and determines that there is a difference between these pieces of information.

As described above, if there is a difference between the actual load information and the virtual load information, the numerical control device 110 (operation control unit 24) decelerates and stops the machine tool 130.

(When there is a difference between the actual machining area and the simulation area) (Pattern in which the workpiece floats up)
<1-1>
4C, for example, the numerical controller 110, in the same manner as described above, creates time series data Xs(0), Xs(1) to Xs(n) of the machine coordinates Xs(i) of the virtual movable parts 134s, 136s from the start time Ts(0) to the time Ts(i) seconds later as operation data for the simulation unit 14. Also, for example, the numerical controller 110, in the same manner as described above, creates time series data Xr(0), Xr(1) to Xr(n) of the machine coordinates Xr(j) of the movable parts 134, 136 from the start time Tr(0) to the time Tr(j) seconds later as operation data for the actual machining unit 12.

<1-2>
Similarly to the above, the simulation unit 14 performs a machining simulation of the virtual workpiece Ws, and the numerical control device 110 (virtual load acquisition unit 18) acquires a contact flag 0/1 (virtual load information) in association with a time Ts(i) (comparison point identification data) as shown in Fig. 4A. For example, in Fig. 4D, at a certain machine coordinate Xs(i) at a certain time Ts(i), the virtual tool Ts does not move from the outside to the inside of the virtual workpiece Ws, and the simulation unit 14 sets the contact flag to 0.

<1-3>
Similarly to the above, the driving unit 120 and the actual machining unit 12 machine the workpiece W, and the driving unit 120 (actual load acquisition unit 16) acquires a contact signal (actual load information) in association with the time Tr(j) (comparison point identification data). For example, in FIG. 4D, when the workpiece W is lifted from the table 136 by chips or the like, or when the movable units 134, 136 or the tool T is lifted, the tool T and the workpiece W come into contact with each other earlier than in the simulation, and the driving unit 120 (actual load acquisition unit 16) outputs a contact signal to the numerical control device 110 earlier than in the simulation. Alternatively, the tool T and the workpiece W come into contact with each other later than in the simulation, and the driving unit 120 (actual load acquisition unit 16) outputs a contact signal to the numerical control device 110 later than in the simulation.

<1-4>
Similarly to the above, the numerical controller 110 (load information determination unit 22) compares the contact signal (actual load information) and the contact flag (virtual load information) based on the time Tr(j) and Ts(i) (comparison point identification data) and determines whether or not there is a difference between these pieces of information. For example, in FIG. 4D, when the tool T and the workpiece W come into contact with each other earlier than the simulation, the numerical controller 110 (load information determination unit 22) detects that the contact signal (actual load information) has been acquired even though the contact flag (virtual load information) has not been set between the time Ts(i-1) and Ts(i), and determines that there is a difference between these pieces of information. Alternatively, when the tool T and the workpiece W come into contact with each other later than the simulation, the numerical controller 110 (load information determination unit 22) does not acquire the contact signal (actual load information) between the time Ts(i-1) and Ts(i), and the contact flag (virtual load information) at this time is 1, so that it determines that there is a difference between these pieces of information.

As described above, if there is a difference between the actual load information and the virtual load information, the numerical control device 110 (operation control unit 24) decelerates and stops the machine tool 130.

[Example 2]
In the second embodiment, machine coordinates (position information of the moving part) are used as the comparison location identification data. This makes it possible to accurately determine whether there is a difference between the actual load information and the virtual load information even when the difference in time (delay) between the simulation and the actual machining is significant due to factors external to the machine tool. FIG. 5A is a diagram showing a case where there is no difference between the actual load information of the moving part in the actual machining part and the virtual load information of the virtual moving part in the simulation part, and FIG. 5B is a diagram showing a case where there is a difference between the actual load information of the moving part in the actual machining part and the virtual load information of the virtual moving part in the simulation part (a pattern where contact is detected only in the simulation part). FIG. 5C is a diagram showing a case where there is a difference between the actual load information of the moving part in the actual machining part and the virtual load information of the virtual moving part in the simulation part (a pattern where contact is detected only in the actual machining part).

(When there is no difference between the actual machining part and the simulation part)
<2-1>
As shown in FIG. 5A, for example, the numerical control device 110 analyzes the machining program, creates time series data Xs(0), Xs(1) to Xs(n) of the machine coordinates Xs(i) of the virtual movable parts 134s, 136s after the time Ts(i) seconds from the start time Ts(0) as operation data for the simulation unit 14, and outputs the data to the simulation unit 14. Also, for example, the numerical control device 110 analyzes the machining program, creates time series data Xr(0), Xr(1) to Xr(n) of the machine coordinates Xr(j) of the movable parts 134, 136 after the time Tr(j) seconds from the start time Tr(0) as operation data for the actual machining unit 12, and outputs the data to the drive unit 120. Here, i and j are any integers from 1 to n. n is an integer of 1 or more.

In this embodiment, the numerical control device 110 analyzes the machining program and creates time-series data of machine coordinates (operation data). However, this embodiment is not limited to this, and the computer constituting the simulation unit 14 or another computer may analyze the machining program and create time-series data of machine coordinates (operation data).

<2-2>
The simulation unit 14 performs a machining simulation of the virtual workpiece Ws by moving the virtual tool Ts and the virtual workpiece Ws relatively based on the machine coordinates Xs(0) to Xs(n) (operation data) output from the numerical control device 110.

The simulation unit 14 calculates contact information indicating whether or not the virtual tool Ts and the virtual workpiece Ws are in contact with each other as virtual load information generated in the virtual movable parts 134s, 136s at a certain machine coordinate Xs(i) at a certain time Ts(i). For example, the simulation unit 14 sets the contact flag to 0 when the virtual tool Ts is outside the virtual workpiece Ws, and sets the contact flag to 1 when the virtual tool Ts moves from the outside to the inside of the virtual workpiece Ws.

The simulation unit 14 also calculates a certain machine coordinate Xs(i) at a certain time Ts(i) as comparison location identification data that identifies a comparison location between the virtual load information and the actual load information. Specifically, the comparison location identification data is data that associates the virtual load information with the actual load information in terms of time series or machining positions. More specifically, the comparison location identification data is data that associates the machine coordinate Xs(i) at which the virtual tool Ts and the virtual workpiece Ws come into contact in the simulation unit 14 with the machine coordinate Xr(j) at which the tool T and the workpiece W come into contact in the actual machining unit 12 in a one-to-one manner. That is, the comparison location identification data is data that identifies the machine coordinate Xs(i) and the machine coordinate Xr(j) as a comparison location between the virtual load information and the actual load information. This allows the load information determination unit 22 to appropriately compare the virtual load information at the machine coordinate Xs(i) with the actual load information at the machine coordinate Xr(j) based on the comparison location identification data.
As described above, the simulation unit 14 may be provided in the numerical control device 110 or may be configured by a computer different from the numerical control device 110.

The numerical control device 110 (virtual load acquisition unit 18) acquires the contact flag 0/1 (virtual load information) in association with the machine coordinates Xs(i) (comparison point identification data), as shown in FIG. 5A.

The simulation unit 14 performs the above-mentioned machining simulation before the actual machining unit 12 operates based on the operation data, and calculates the virtual load information and the comparison location data in advance. In addition, the virtual load acquisition unit 18 may acquire the virtual load information in advance in association with the comparison location identification data and temporarily store it in the storage unit 20 before the actual machining unit 12 operates based on the operation data.

<2-3>
The driving unit 120 drives the motor 132 and the movable units 134, 136 of the actual machining unit 12 based on the machine coordinates Xr(0) to Xr(n) (operation data) output from the numerical control device 110. As a result, the actual machining unit 12 performs machining of the workpiece W by moving the tool T and the workpiece W relative to each other.

The driving unit 120 (actual load acquisition unit 16) acquires contact information indicating whether or not the tool T and workpiece W are in contact as load information generated in the movable parts 134, 136 at a certain machine coordinate Xr(j) at a certain time Tr(j). For example, the driving unit 120 (actual load acquisition unit 16) monitors the output (command or feedback information) of the motor 132, and when the output of the motor 132 exceeds a certain threshold, it determines that the tool T and workpiece W are in contact, and outputs a contact signal to the numerical control device 110.

The drive unit 120 (actual load acquisition unit 16) acquires the contact signal (actual load information) in association with the machine coordinates Xr(j) (comparison point identification data).

<2-4>
The numerical control device 110 (load information determination unit 22) compares the contact signal (actual load information) and the contact flag (virtual load information) based on the machine coordinates Xr(j), Xs(i) (comparison point identification data) and determines whether there is a difference between these pieces of information. For example, in FIG. 5A, the numerical control device 110 (load information determination unit 22) determines that there is no difference between the actual load information and the virtual load information based on the machine coordinates Xr(j), Xs(i) (comparison point identification data), since the machine coordinates Xr(j) (comparison point identification data) at which the contact signal (actual load information) is detected in the actual machining unit 12 and the machine coordinates Xs(i-1), Xs(i) (comparison point identification data) at which the contact flag (virtual load information) changes from 0 to 1 in the simulation unit 14 satisfy the following inequality for all axes p operating between i-1 and i.
|Xrp(j)-Xsp(i)|≦|Xsp(i)-Xsp(i-1)|

In addition, if there are multiple machine coordinates Xr(j) (comparison location identification data) where a contact signal (actual load information) is detected in the actual machining unit 12, and multiple machine coordinates Xs(i) (comparison location identification data) where the contact flag (virtual load information) changes from 0 to 1 in the simulation unit 14, the above judgment may be performed in the order of contact.

The load information determination unit 22 makes the above-mentioned determination in real time while the actual machining unit 12 is operating, based on the virtual load information obtained in advance by the simulation unit 14 and the actual load information obtained in real time by the actual machining unit 12.
The load information determining unit 22 may extract and compare only the virtual load information and the actual load information of a specific section in the comparison point specifying data.

If there is no difference between the actual load information and the virtual load information, the numerical control device 110 (operation control unit 24) does not impose any operational restrictions.

As mentioned above, the load information determination unit 22 may be provided in the numerical control device 110, or in the drive unit 120 (servo control unit, amplifier), or may be configured by a computer separate from the numerical control device 110 and the drive unit 120.

(When there is a difference between the actual machining part and the simulation part) (Pattern in which contact is detected only in the simulation part)
<2-1>
5B, for example, the numerical control device 110, in the same manner as described above, creates time series data Xs(0), Xs(1) to Xs(n) of the machine coordinates Xs(i) of the virtual movable parts 134s, 136s after the time Ts(i) seconds from the start time Ts(0) as operation data for the simulation unit 14. Also, for example, the numerical control device 110, in the same manner as described above, creates time series data Xr(0), Xr(1) to Xr(n) of the machine coordinates Xr(j) of the movable parts 134, 136 after the time Tr(j) seconds from the start time Tr(0) as operation data for the actual machining unit 12.

<2-2>
As described above, the simulation unit 14 performs a machining simulation of the virtual workpiece Ws, and the numerical control device 110 (virtual load acquisition unit 18) acquires the contact flag 0/1 (virtual load information) in association with the machine coordinates Xs(i) (comparison point identification data), as shown in FIG. 5B.

<2-3>
Similarly to the above, the driving unit 120 and the actual machining unit 12 machine the workpiece W, and the driving unit 120 (actual load acquisition unit 16) acquires a contact signal (actual load information) in association with the machine coordinates Xr(j) (comparison point identification data). For example, in Fig. 5B, the tool T and the workpiece W do not come into contact with each other due to damage to the tool or incorrect installation, and the driving unit 120 (actual load acquisition unit 16) does not acquire a contact signal and does not output the contact signal to the numerical control device 110.

If contact is detected at another location after machining has progressed to a certain extent, the drive unit 120 (actual load acquisition unit 16) may output a contact signal (actual load information) and machine coordinates Xr(k) (comparison location identification data) to the numerical control device 110.

<2-4>
As described above, the numerical control device 110 (load information determination unit 22) compares the contact signal (actual load information) and the contact flag (virtual load information) based on the machine coordinates Xr(j) and Xs(i) (comparison point identification data) and determines whether or not there is a difference between these pieces of information. For example, in Fig. 5B, the numerical control device 110 (load information determination unit 22) does not acquire a contact signal (actual load information) in the actual machining unit 12, while the simulation unit 14 has a contact flag (virtual load information) of 1, and therefore determines that there is a difference between these pieces of information. Alternatively, the numerical control device 110 (load information determination unit 22) determines that there is a difference between the actual load information and the virtual load information because the machine coordinate Xr(k) (comparison point identification data) at which a contact signal (actual load information) is detected in the actual machining unit 12 and the machine coordinates Xs(i-1), Xs(i) (comparison point identification data) at which the contact flag (virtual load information) changes from 0 to 1 in the simulation unit 14 do not satisfy the following inequality for all axes p operating between i-1 and i:
|Xrp(k)-Xsp(i)|≦|Xsp(i)-Xsp(i-1)|

If there is a difference between the actual load information and the virtual load information, the numerical control device 110 (motion control unit 24) decelerates and stops the machine tool 130. The numerical control device 110 (motion control unit 24) may immediately stop the motor output, or may perform a predetermined emergency stop operation. That is, the numerical control device 110 (motion control unit 24) performs output restriction for operating the movable parts 134, 136 in the actual machining unit 12, a preset retraction operation of the movable parts 134, 136, or an immediate deceleration and stop of the operation of the movable parts 134, 136.

At this time, the machine tool operator can recognize whether the tool T has been attached incorrectly or is damaged by comparing the machine coordinates where contact (interference) was detected in the machining simulation with the machine coordinates where contact (interference) was not detected in the actual machining, which correspond to the machine coordinates where contact (interference) was detected in the actual machining.

(When there is a difference between the actual machining part and the simulation part) (Pattern in which contact is detected only in the actual machining part)
<2-1>
5C, for example, the numerical controller 110, in the same manner as described above, creates time series data Xs(0), Xs(1) to Xs(n) of the machine coordinates Xs(i) of the virtual movable parts 134s, 136s after the time Ts(i) seconds from the start time Ts(0) as operation data for the simulation unit 14. Also, for example, the numerical controller 110, in the same manner as described above, creates time series data Xr(0), Xr(1) to Xr(n) of the machine coordinates Xr(j) of the movable parts 134, 136 after the time Tr(j) seconds from the start time Tr(0) as operation data for the actual machining unit 12.

<2-2>
As described above, the simulation unit 14 performs a machining simulation of the virtual workpiece Ws, and the numerical control device 110 (virtual load acquisition unit 18) acquires a contact flag 0/1 (virtual load information) in association with the machine coordinate Xs(i) (comparison point identification data) as shown in Fig. 5B. In Fig. 5C, at a certain machine coordinate Xs(i) at a certain time Ts(i), the virtual tool Ts does not move from the outside to the inside of the virtual workpiece Ws, and the simulation unit 14 sets the contact flag to 0.

If contact is detected at another location after machining has progressed to a certain extent, the numerical control device 110 (virtual load acquisition unit 18) may acquire a contact flag 1 (virtual load information) in association with the machine coordinate Xs(k) (comparison location identification data) where the contact was detected.

<2-3>
As described above, the drive unit 120 and the actual processing unit 12 process the workpiece W, and the drive unit 120 (actual load acquisition unit 16) acquires a contact signal (actual load information) in association with the machine coordinates Xr(j) (comparison point identification data).

<2-4>
Similarly to the above, the numerical control device 110 (load information determination unit 22) compares the contact signal (actual load information) and the contact flag (virtual load information) based on the machine coordinates Xr(j) and Xs(i) (comparison point identification data) and determines whether or not there is a difference between these pieces of information. For example, in Fig. 5C, the numerical control device 110 (load information determination unit 22) determines that there is a difference between these pieces of information because the contact flag (virtual load information) is 0 in the machine coordinates Xs(i) (comparison point identification data) in the simulation unit 14, which corresponds to the machine coordinates Xr(j) (comparison point identification data) at which the contact signal (actual load information) was detected in the actual machining unit 12. Alternatively, the numerical control device 110 (load information determination unit 22) determines that there is a difference between the actual load information and the virtual load information because the machine coordinate Xr(j) (comparison point identification data) at which a contact signal (actual load information) is detected in the actual machining unit 12 and the machine coordinates Xs(k-1), Xs(k) (comparison point identification data) at which the contact flag (virtual load information) changes from 0 to 1 in the simulation unit 14 do not satisfy the following inequality for all axes p operating between i-1 and i:
|Xrp(j)-Xsp(k)|≦|Xsp(k)-Xsp(k-1)|

As described above, if there is a difference between the actual load information and the virtual load information, the numerical control device 110 (operation control unit 24) decelerates and stops the machine tool 130.

[Example 3]
In the third embodiment, the operation data is used as the comparison location identification data. By recording the machine coordinates in the operation data, it becomes easy to identify the problem location of the machining data. FIG. 6A is a diagram showing a case where there is no difference between the actual load information of the moving part in the real machining part and the virtual load information of the virtual moving part in the simulation part, and FIG. 6B is a diagram showing a case where there is a difference between the actual load information of the moving part in the real machining part and the virtual load information of the virtual moving part in the simulation part (a pattern where contact is detected only in the simulation part). FIG. 6C is a diagram showing a case where there is a difference between the actual load information of the moving part in the real machining part and the virtual load information of the virtual moving part in the simulation part (a pattern where contact is detected only in the real machining part).

(When there is no difference between the actual machining part and the simulation part)
<3-1>
As shown in FIG. 6A, for example, the simulation unit 14 analyzes the machining program, and creates time series data Xs(0), Xs(1) to Xs(n) of the machine coordinates Xs(i) of the virtual movable parts 134s, 136s after the time Ts(i) seconds from the start time Ts(0) as operation data for the simulation unit 14. On the other hand, for example, the numerical control device 110 analyzes the machining program, and creates time series data Xr(0), Xr(1) to Xr(n) of the machine coordinates Xr(j) of the movable parts 134, 136 after the time Tr(j) seconds from the start time Tr(0) as operation data for the actual machining unit 12, and outputs them to the drive unit 120. Here, i and j are any integers from 1 to n. n is an integer of 1 or more.

<3-2>
The simulation unit 14 performs a machining simulation of the virtual workpiece Ws by moving the virtual tool Ts and the virtual workpiece Ws relatively based on the machine coordinates Xs(0) to Xs(n) (operation data).

The simulation unit 14 calculates contact information indicating whether or not the virtual tool Ts and the virtual workpiece Ws are in contact as virtual load information occurring on the virtual movable parts 134s, 136s at a certain machine coordinate Xs(i) at a certain time Ts(i). The simulation unit 14 also calculates a certain machine coordinate Xs(i) at a certain time Ts(i) as comparison location identification data that identifies a comparison location between the virtual load information and the actual load information. For example, when the virtual tool Ts invades the virtual workpiece Ws from the outside to the inside between the machine coordinates Xs(j-1) and Xs(j), the simulation unit 14 adds the coordinate of the machine coordinate Xs(j) in the format of ",Ln X_Y_Z_" in association with the command block in the operation data (virtual load information and comparison location identification data). Here, n is an integer of 1 or more, and when contact occurs multiple times during one block, n is incremented and multiple entries are made.

In addition, when the operation data is a minute line segment, the coordinates of the machine coordinates Xs(j) may be added in units of one block instead of in units of command blocks (virtual load information and comparison point identification data). Also, although an example has been given of a case in which there are three feed axes, this embodiment can also be applied to cases in which there are four or more feed axes.

The comparison location identification data is data that associates the virtual load information with the actual load information in terms of time series or machining positions. More specifically, the comparison location identification data is data that creates a one-to-one correspondence between the machine coordinate Xs(i) where the virtual tool Ts and virtual workpiece Ws come into contact in the simulation unit 14 and the machine coordinate Xr(j) where the tool T and workpiece W come into contact in the actual machining unit 12. In other words, the comparison location identification data is data that identifies the machine coordinate Xs(i) and the machine coordinate Xr(j) as the comparison location between the virtual load information and the actual load information. This allows the load information determination unit 22 to appropriately compare the virtual load information at the machine coordinate Xs(i) with the actual load information at the machine coordinate Xr(j) based on the comparison location identification data.

The numerical control device 110 (virtual load acquisition unit 18) acquires ",Ln X_Y_Z_" (virtual load information and comparison location identification data) that has been added to the operation data, as shown in FIG. 6A.

The simulation unit 14 performs the above-mentioned machining simulation before the actual machining unit 12 operates based on the operation data, and calculates the virtual load information and the comparison location data in advance. In addition, the virtual load acquisition unit 18 may acquire the virtual load information in advance in association with the comparison location identification data and temporarily store it in the storage unit 20 before the actual machining unit 12 operates based on the operation data.

<3-3>
The driving unit 120 drives the motor 132 and the movable units 134, 136 of the actual machining unit 12 based on the machine coordinates Xr(0) to Xr(n) (operation data) output from the numerical control device 110. As a result, the actual machining unit 12 performs machining of the workpiece W by moving the tool T and the workpiece W relative to each other.

The driving unit 120 (actual load acquisition unit 16) acquires contact information indicating whether or not the tool T and workpiece W are in contact as load information generated in the movable parts 134, 136 at a certain machine coordinate Xr(j) at a certain time Tr(j). For example, the driving unit 120 (actual load acquisition unit 16) monitors the output (command or feedback information) of the motor 132, and when the output of the motor 132 exceeds a certain threshold, it determines that the tool T and workpiece W are in contact, and outputs a contact signal to the numerical control device 110.

The drive unit 120 (actual load acquisition unit 16) acquires the contact signal (actual load information) in association with the machine coordinates Xr(j) (comparison point identification data).

<3-4>
The numerical control device 110 (load information determination unit 22) compares the contact signal (actual load information) with the presence or absence of contact (virtual load information) based on the machine coordinates Xr(j) and Xs(i) (comparison point identification data), and determines whether or not there is a difference between these pieces of information. For example, in FIG. 6A, the numerical control device 110 (load information determination unit 22) determines that there is no difference between the actual load information and the virtual load information because the machine coordinates Xr(j) (comparison point identification data) at which the contact signal (actual load information) was detected in the actual machining unit 12 and the machine coordinates Xs(i) (comparison point identification data) indicated by ",Ln X_Y_Z_" added to the operation data in the simulation unit 14 satisfy the following inequality for all axes p operating between i-1 and i.
|Xrp(j)-Xsp(i)|≦|Xsp(i)-Xsp(i-1)|
When a plurality of ",Ln X_Y_Z" (virtual load information and comparison location specifying data) are described in the operation data, the above determination may be performed in ascending order of the value of n.

The load information determination unit 22 makes the above-mentioned determination in real time while the actual machining unit 12 is operating, based on the virtual load information obtained in advance by the simulation unit 14 and the actual load information obtained in real time by the actual machining unit 12.
The load information determining unit 22 may extract and compare only the virtual load information and the actual load information of a specific section in the comparison point specifying data.

If there is no difference between the actual load information and the virtual load information, the numerical control device 110 (operation control unit 24) does not impose any operational restrictions.

Usually, the period for acquiring the position of the movable part in the actual machining unit is shorter than the simulation period, so the error in the machine coordinate Xr(j) at which a contact signal is detected in the actual machining unit 12 can be ignored. However, when the error in the simulation unit 14 is smaller than the error in the actual machining unit, the load information determination unit 22 may determine that there is no difference between the actual load information and the virtual load information when a machine coordinate Xs(i) that contacts in the simulation unit 14 exists between the machine coordinates Xr(j-1) and Xr(j) in the actual machining unit 12. In other words, it may be confirmed that the following equation holds for all axes p that operate between i-1 and i.
|Xrp(j)-Xsp(i)|≦|Xrp(j)-Xrp(j-1)|

(When there is a difference between the actual machining part and the simulation part) (Pattern in which contact is detected only in the simulation part)
<3-1>
6B, for example, the simulation unit 14, in the same manner as described above, creates time series data Xs(0), Xs(1) to Xs(n) of the machine coordinates Xs(i) of the virtual movable parts 134s, 136s from the start time Ts(0) to the time Ts(i) seconds later as operation data for the simulation unit 14. On the other hand, for example, the numerical control device 110, in the same manner as described above, creates time series data Xr(0), Xr(1) to Xr(n) of the machine coordinates Xr(j) of the movable parts 134, 136 from the start time Tr(0) to the time Tr(j) seconds later as operation data for the actual machining unit 12.

<3-2>
As described above, the simulation unit 14 performs a machining simulation of the virtual workpiece Ws, and the numerical control device 110 (virtual load acquisition unit 18) acquires “,Ln X_Y_Z_” (virtual load information and comparison point identification data) added to the operation data, as shown in FIG. 6B.

<3-3>
Similarly to the above, the driving unit 120 and the actual machining unit 12 machine the workpiece W, and the driving unit 120 (actual load acquisition unit 16) acquires a contact signal (actual load information) in association with the machine coordinates Xr(j) (comparison point identification data). For example, in Fig. 6B, the tool T and the workpiece W do not come into contact with each other due to damage to the tool or incorrect installation, and the driving unit 120 (actual load acquisition unit 16) does not acquire a contact signal and does not output the contact signal to the numerical control device 110.

<3-4>
As described above, the numerical control device 110 (load information determination unit 22) compares the contact signal (actual load information) with the presence or absence of contact (virtual load information) based on the machine coordinates Xr(j), Xs(i) (comparison point identification data) and determines whether or not there is a difference between these pieces of information. For example, in Fig. 6B, the numerical control device 110 (load information determination unit 22) determines that there is a difference between these pieces of information because the drive unit 120 (actual load acquisition unit 16) does not acquire a contact signal in the actual machining unit 12 even though the block (comparison point identification data) corresponding to the block in which ",Ln X_Y_Z_" (virtual load information and comparison point identification data) is written in the operation data of the simulation unit 14 has passed.

If there is a difference between the actual load information and the virtual load information, the numerical control device 110 (motion control unit 24) decelerates and stops the machine tool 130. The numerical control device 110 (motion control unit 24) may immediately stop the motor output, or may perform a predetermined emergency stop operation. That is, the numerical control device 110 (motion control unit 24) limits the output to operate the movable parts 134, 136 in the actual machining unit 12, performs a preset retraction operation of the movable parts 134, 136, or immediately decelerates and stops the operation of the movable parts 134, 136.

The display unit 28 may also display the machine coordinates Xs(i) of operation data in which contact (interference) between the virtual tool Ts and the virtual workpiece Ws has been detected in the simulation unit 14 in a color different from that of other operation data, or may display them in a flashing color. This allows the operator of the machine tool to easily recognize the machine coordinates Xs(i) of operation data in which contact (interference) between the virtual tool Ts and the virtual workpiece Ws has been detected in the simulation unit 14.

(When there is a difference between the actual machining part and the simulation part) (Pattern in which contact is detected only in the actual machining part)
<3-1>
6C, for example, the simulation unit 14, in the same manner as described above, creates time series data Xs(0), Xs(1) to Xs(n) of the machine coordinates Xs(i) of the virtual movable parts 134s, 136s from the start time Ts(0) to the time Ts(i) seconds later as operation data for the simulation unit 14. Meanwhile, for example, the numerical control device 110, in the same manner as described above, creates time series data Xr(0), Xr(1) to Xr(n) of the machine coordinates Xr(j) of the movable parts 134, 136 from the start time Tr(0) to the time Tr(j) seconds later as operation data for the actual machining unit 12.

<3-2>
Similarly to the above, the simulation unit 14 performs a machining simulation of the virtual workpiece Ws, and the numerical control device 110 (virtual load acquisition unit 18) acquires ",Ln X_Y_Z_" (virtual load information and comparison location identification data) added to the operation data as shown in Fig. 6C. For example, in Fig. 6C, the virtual tool Ts does not enter the inside of the virtual workpiece Ws from the outside, and there is no description of ",Ln X_Y_Z_" (virtual load information and comparison location identification data) in the operation data, so the numerical control device 110 (virtual load acquisition unit 18) does not acquire ",Ln X_Y_Z_" (virtual load information and comparison location identification data) added to the operation data.

<3-3>
As described above, the drive unit 120 and the actual processing unit 12 process the workpiece W, and the drive unit 120 (actual load acquisition unit 16) acquires a contact signal (actual load information) in association with the machine coordinates Xr(j) (comparison point identification data).

<3-4>
As described above, the numerical control device 110 (load information determination unit 22) compares the contact signal (actual load information) with the presence or absence of contact (virtual load information) based on the machine coordinates Xr(j) and Xs(i) (comparison point identification data) and determines whether or not there is a difference between these pieces of information. For example, in Fig. 6C, the numerical control device 110 (load information determination unit 22) determines that there is a difference between these pieces of information because ",Ln X_Y_Z_" (virtual load information and comparison point identification data) is not written in the block of the operation data of the simulation unit 14 corresponding to the machine coordinates Xr(j) (comparison point identification data) where the contact signal (actual load information) was detected in the actual machining unit 12.

As described above, if there is a difference between the actual load information and the virtual load information, the numerical control device 110 (operation control unit 24) decelerates and stops the machine tool 130.

Furthermore, as described above, the display unit 28 may display the machine coordinate Xr(j) at which contact (interference) between the tool T and the workpiece W is detected in the actual machining unit 12 in a color different from other operation data, or may display it in a flashing color. This allows the operator of the machine tool to easily recognize the machine coordinate Xr(j) at which contact (interference) between the tool T and the workpiece W is detected in the actual machining unit 12.

[Example 4]
In the fourth embodiment, the magnitude of the load (energy) generated on the moving part when machining the workpiece is used as the actual load information, and the magnitude of the load (energy) generated on the virtual moving part when machining the virtual workpiece is used as the virtual load information. By acquiring the magnitude of the load (energy) instead of the presence or absence of contact, it becomes possible to more accurately determine the contact between the tool and the workpiece, for example, when cutting in gradually.

<4-1>
As shown in FIG. 7, for example, the numerical control device 110 analyzes the machining program, creates time series data Xs(0), Xs(1) to Xs(n) of the machine coordinates Xs(i) of the virtual movable parts 134s, 136s after the time Ts(i) seconds from the start time Ts(0) as operation data for the simulation unit 14, and outputs the data to the simulation unit 14. Also, for example, the numerical control device 110 analyzes the machining program, creates time series data Xr(0), Xr(1) to Xr(n) of the machine coordinates Xr(j) of the movable parts 134, 136 after the time Tr(j) seconds from the start time Tr(0) as operation data for the actual machining unit 12, and outputs the data to the drive unit 120. Here, i and j are any integers from 1 to n. n is an integer of 1 or more.

In this embodiment, the numerical control device 110 analyzes the machining program and creates time series data (operation data) of the machine coordinates. However, this embodiment is not limited to this, and the computer constituting the simulation unit 14 or another computer may analyze the machining program and create time series data (operation data) of the machine coordinates.

<4-2>
The simulation unit 14 performs a machining simulation of the virtual workpiece Ws by moving the virtual tool Ts and the virtual workpiece Ws relatively based on the machine coordinates Xs(0) to Xs(n) (operation data) output from the numerical control device 110.

The simulation unit 14 calculates the total amount of virtual load Ws(i) [J/s] (energy Ws × t) as virtual load information generated on the virtual moving parts 134s and 136s at a certain machine coordinate Xs(i) at a certain time Ts(i).

An example of calculation of the total amount of virtual load Ws(i) [J/s] (energy Ws×t) is shown below.
Consider the case where the virtual movable parts 134s, 136s move from the machine coordinate Xs(i-1) at time Ts(i-1) to the machine coordinate Xs(i) at time Ts(i). Assuming that the energy required to remove and machine the virtual workpiece Ws is proportional to the volume to be removed (proportionality constant k), and that the total friction coefficient when operating a movable part with mass m is always constant (n), the total virtual load Ws(i) per unit time from time T(i-1) to T(i) can be expressed by the following formula.

In the numerator on the right side of the above equation, the first item is the energy required to remove the virtual workpiece Ws, the second item is the change in kinetic energy, the third item is the change in potential energy, and the fourth item is the energy consumed by the movement of the virtual moving part.

Vs(i) is the volume of the removal area, which is the overlapping area of the area through which the virtual tool Ts passed between Ts(i-1) and Ts(i) and the area of the virtual workpiece Ws. Vs(i) is the speed of i and can be expressed by the following formula.

The simulation unit 14 also calculates a certain machine coordinate Xs(i) at a certain time Ts(i) as comparison location identification data that identifies a comparison location between the virtual load information and the actual load information. Specifically, the comparison location identification data is data that associates the virtual load information with the actual load information in terms of time series or machining positions. More specifically, the comparison location identification data is data that associates the time Ts(i) at which the virtual tool Ts and the virtual workpiece Ws come into contact with each other in the simulation unit 14 with the time Tr(j) at which the tool T and the workpiece W come into contact with each other in the actual machining unit 12 in a one-to-one manner. That is, the comparison location identification data is data that identifies the time Ts(i) and the time Tr(j) as the comparison location between the virtual load information and the actual load information. This allows the load information determination unit 22 to appropriately compare the virtual load information at the time Ts(i) with the actual load information at the time Tr(j) based on the comparison location identification data.
As described above, the simulation unit 14 may be provided in the numerical control device 110 or may be configured by a computer different from the numerical control device 110.

The numerical control device 110 (virtual load acquisition unit 18) acquires the load Ws(i) [J/s] (energy Ws x t) (virtual load information) in association with the time Ts(i) (comparison point identification data) as shown in FIG. 7.

The simulation unit 14 performs the above-mentioned machining simulation before the actual machining unit 12 operates based on the operation data, and calculates the virtual load information and the comparison location data in advance. In addition, the virtual load acquisition unit 18 may acquire the virtual load information in advance in association with the comparison location identification data and temporarily store it in the storage unit 20 before the actual machining unit 12 operates based on the operation data.

<4-3>
The driving unit 120 drives the motor 132 and the movable units 134, 136 of the actual machining unit 12 based on the machine coordinates Xr(0) to Xr(n) (operation data) output from the numerical control device 110. As a result, the actual machining unit 12 performs machining of the workpiece W by moving the tool T and the workpiece W relative to each other.

The driving unit 120 (actual load acquisition unit 16) calculates the total motor load Wr(j) [J/s] (energy Wr x t) as actual load information occurring on the movable parts 134, 136 at a certain machine coordinate Xr(j) at a certain time Tr(j). The calculation of the load Wr(j) [J/s] (energy Wr x t) may be the same as the example of the calculation of the load Ws(i) [J/s] (energy Ws x t) described above.

If the machine tool is an EDM machine, simply add the power flowing through the tool to the total motor load.

As shown in FIG. 7, the drive unit 120 (actual load acquisition unit 16) acquires the load Wr(j) [J/s] (energy Wr×t) (actual load information) in association with the time Tr(j) (comparison point identification data).

<4-4>
The numerical control device 110 (load information determination unit 22) compares the load Wr(j) [J/s] (energy Wr×t) (actual load information) with the load Ws(i) [J/s] (energy Ws×t) (virtual load information) based on the times Tr(j) and Ts(i) (comparison point identification data), and determines whether there is a difference between these pieces of information. For example, in Fig. 7, the numerical control device 110 (load information determination unit 22) finds the minimum j (jmin) and maximum j (jmax) that satisfy the following formula at the time Ts(i).
Ts(i-1)≦Tr(j)<Ts(i)

The numerical control device 110 (load information determination unit 22) determines whether the following formula is satisfied at i. If the following formula is satisfied, the numerical control device 110 (load information determination unit 22) determines that there is no difference between the actual load information and the virtual load information.

Here, jmin and jmax are the minimum and maximum j that satisfy Ts(i-1)≦Tr(j)<Ts(i), ΔTs is the simulation period, ΔTr is the period for acquiring the motor output in the actual machining section, and ΔW[J] is a certain threshold value indicating the motor load. Note that the above formula is based on the premise that ΔTs>ΔTr.

If the motor output is less than a certain threshold, it is possible to assume that the workpiece and tool are not in contact with each other in the actual machining area, and no comparison is made.

The load information determination unit 22 makes the above-mentioned determination in real time while the actual machining unit 12 is operating, based on the virtual load information obtained in advance by the simulation unit 14 and the actual load information obtained in real time by the actual machining unit 12.
The load information determining unit 22 may extract and compare only the virtual load information and the actual load information of a specific section in the comparison point specifying data.

If there is no difference between the actual load information and the virtual load information, the numerical control device 110 (operation control unit 24) does not impose any operational restrictions.

As mentioned above, the load information determination unit 22 may be provided in the numerical control device 110, or in the drive unit 120 (servo control unit, amplifier), or may be configured by a computer separate from the numerical control device 110 and the drive unit 120.

[Example 5]
In the above-mentioned first to fourth embodiments, the operation of the actual machining is restricted on the assumption that there is a problem in the actual machining. In the fifth embodiment, when there is a problem in the settings of the machining simulation, the settings of the machining simulation are changed (corrected). In this way, the difference between the actual load information and the virtual load information is reflected in the machining simulation, thereby improving the simulation accuracy.

<5-1>
As shown in FIG. 8, for example, the numerical control device 110 analyzes the machining program, creates time series data Xs(0), Xs(1) to Xs(n) of the machine coordinates Xs(i) of the virtual movable parts 134s, 136s after the time Ts(i) seconds from the start time Ts(0) as operation data for the simulation unit 14, and outputs the data to the simulation unit 14. Also, for example, the numerical control device 110 analyzes the machining program, creates time series data Xr(0), Xr(1) to Xr(n) of the machine coordinates Xr(j) of the movable parts 134, 136 after the time Tr(j) seconds from the start time Tr(0) as operation data for the actual machining unit 12, and outputs the data to the drive unit 120. Here, i and j are any integers from 1 to n. n is an integer of 1 or more.

In this embodiment, the numerical control device 110 analyzes the machining program and creates time-series data of machine coordinates (operation data). However, this embodiment is not limited to this, and the computer constituting the simulation unit 14 or another computer may analyze the machining program and create time-series data of machine coordinates (operation data).

<5-2>
The driving unit 120 drives the motor 132 and the movable units 134, 136 of the actual machining unit 12 based on the machine coordinates Xr(0) to Xr(n) (operation data) output from the numerical control device 110. As a result, the actual machining unit 12 performs machining of the workpiece W by moving the tool T and the workpiece W relative to each other.

The driving unit 120 (actual load acquisition unit 16) acquires contact information indicating whether or not the tool T and workpiece W are in contact as load information generated in the movable parts 134, 136 at a certain machine coordinate Xr(j) at a certain time Tr(j). For example, the driving unit 120 (actual load acquisition unit 16) monitors the output (command or feedback information) of the motor 132, and sets the contact signal to 0 if the output of the motor 132 does not exceed a certain threshold, and determines that the tool T and workpiece W are in contact and sets the contact signal to 1 if the output of the motor 132 exceeds a certain threshold.

The drive unit 120 (actual load acquisition unit 16) acquires the contact signal (actual load information) in association with the machine coordinates Xr(j) (comparison point identification data).

The comparison location identification data is data that associates the virtual load information with the actual load information in terms of time series or machining positions. More specifically, the comparison location identification data is data that creates a one-to-one correspondence between the machine coordinate Xs(i) where the virtual tool Ts and virtual workpiece Ws come into contact in the simulation unit 14 and the machine coordinate Xr(j) where the tool T and workpiece W come into contact in the actual machining unit 12. In other words, the comparison location identification data is data that identifies the machine coordinate Xs(i) and the machine coordinate Xr(j) as the comparison location between the virtual load information and the actual load information. This allows the load information determination unit 22 to appropriately compare the virtual load information at the machine coordinate Xs(i) with the actual load information at the machine coordinate Xr(j) based on the comparison location identification data.

<5-3>
The simulation unit 14 performs a machining simulation of the virtual workpiece Ws by moving the virtual tool Ts and the virtual workpiece Ws relatively based on the machine coordinates Xs(0) to Xs(n) (operation data) output from the numerical control device 110.

The simulation unit 14 calculates contact information indicating whether or not the virtual tool Ts and the virtual workpiece Ws are in contact with each other as virtual load information generated in the virtual movable parts 134s, 136s at a certain machine coordinate Xs(i) at a certain time Ts(i). For example, the simulation unit 14 sets the contact flag to 0 when the virtual tool Ts is outside the virtual workpiece Ws, and sets the contact flag to 1 when the virtual tool Ts moves from the outside to the inside of the virtual workpiece Ws.

Furthermore, the simulation unit 14 calculates a certain machine coordinate Xs(i) at a certain time Ts(i) as comparison point specifying data for specifying a comparison point between the virtual load information and the actual load information.
As described above, the simulation unit 14 may be provided in the numerical control device 110 or may be configured by a computer different from the numerical control device 110.

The numerical control device 110 (virtual load acquisition unit 18) acquires the contact flag 0/1 (virtual load information) in association with the machine coordinates Xs(i) (comparison point identification data).

<5-4>
The simulation unit 14 (load information determination unit 22) compares the contact signal (actual load information) with the contact flag (virtual load information) based on the machine coordinates Xr(j), Xs(i) (comparison point identification data) and determines whether there is a difference between these pieces of information. For example, in Fig. 8, the numerical control device 110 (load information determination unit 22) determines that there is a difference between the actual load information and the virtual load information based on the machine coordinates Xr(j), Xs(i) (comparison point identification data) when the machine coordinate Xr(j) (comparison point identification data) at which the contact signal (actual load information) is detected in the actual machining unit 12 is different from the machine coordinate Xs(i) (comparison point identification data) at which the contact flag (virtual load information) changes from 0 to 1 in the simulation unit 14.

The load information determination unit 22 may extract and compare only the virtual load information and actual load information for a specific section in the comparison point identification data.

If there is a difference between the actual load information and the virtual load information, the simulation unit 14 (correction unit 26) changes (corrects) the preconditions of the simulation unit 14. The preconditions of the simulation unit 14 are, for example, items described in the operation data, and include preconditions related to the virtual tool, virtual workpiece, and virtual moving parts.

For example, in FIG. 8, the simulation unit 14 (correction unit 26) calculates the difference between the machine coordinate in the simulation unit 14 corresponding to the machine coordinate Xr(j) at which a contact signal (actual load information) is detected in the actual machining unit 12 and the machine coordinate of the boundary of the virtual workpiece Ws, and reflects this difference in the preconditions of the simulation unit so as to change the setting value of the radius R of the virtual tool Ts.

Alternatively, the simulation unit 14 (correction unit 26) may calculate the difference between the machine coordinate Xr(j) at which a contact signal (actual load information) is detected in the actual machining unit 12 and the machine coordinate Xs(i) at which a contact flag (virtual load information) is detected in the simulation unit 14, and use this difference as a correction amount for the virtual tool Ts, and reflect this difference in the preconditions of the simulation unit so as to change (correct) the setting value of the virtual tool Ts by this correction amount.

Alternatively, the simulation unit 14 (correction unit 26) may identify a process in the operation data where there is a difference in information based on the machine coordinate Xr(j) (comparison location identification data) where a contact signal (actual load information) is detected in the actual machining unit 12 and the machine coordinate Xs(i) (comparison location identification data) where the contact flag (virtual load information) changes from 0 to 1 in the simulation unit 14, and change (correct) the preconditions for the machining simulation.

As described above, according to the machining load judgment system 10 of this embodiment, virtual load information of the machining simulation is acquired in association with the comparison location identification data, and actual load information of the actual machining is acquired in association with the comparison location identification data, so that these load information can be appropriately compared based on the comparison location identification data without performing a machining simulation in real time for the actual machining. Therefore, the machining simulation can be performed in advance before the actual machining, there is no need to shorten the processing time of the machining simulation to match the operating time of the actual machining, and the accuracy of the machining simulation is not limited, that is, the accuracy of the machining simulation can be improved. Therefore, the accuracy of detection of the difference between the machining simulation and actual machining can be improved, and malfunctions that could not be prevented in the past can be correctly detected.

In the technology disclosed in Patent Document 1, when repeating the same operation with the same operating data, it is necessary to constantly perform the same simulation, which requires resources. In this regard, in this embodiment, it is not necessary to perform a machining simulation every time actual machining is performed, and resources can be reduced compared to the technology disclosed in Patent Document 1.

Although the present disclosure has been described in detail, the present disclosure is not limited to the individual embodiments described above. Various additions, substitutions, modifications, partial deletions, etc. are possible to these embodiments without departing from the gist of the present disclosure, or without departing from the spirit of the present disclosure derived from the contents described in the claims and their equivalents. These embodiments can also be implemented in combination. For example, in the above-mentioned embodiments, the order of each operation and the order of each process are shown as examples, and are not limited to these. The same applies when numerical values or formulas are used to explain the above-mentioned embodiments.

The following supplementary notes are further disclosed regarding the above-described embodiment and modified examples.
(Appendix 1)
The processing load determination system (10) comprises:
an actual machining unit (12) having a movable unit (134, 136) on which a tool (T) or a workpiece (W) is provided, and machining the workpiece (W) by relatively moving the tool (T) and the workpiece (W) based on operation data;
a simulation unit (14) that performs a machining simulation of the virtual workpiece (Ws) by relatively moving the virtual tool (Ts) and the virtual workpiece (Ws) based on the operation data in a virtual space (VS) including a virtual tool (Ts), a virtual workpiece (Ws), and a virtual movable part (134s, 136s) corresponding to the tool (T), the workpiece (W), and the movable part (134, 136), respectively;
a virtual load acquisition unit (18) that acquires virtual load information generated on the virtual moving parts (134s, 136s), the virtual load information being obtained by a machining simulation performed by the simulation unit (14);
an actual load acquisition unit (16) that acquires actual load information generated on the movable unit (134, 136) obtained by machining by the actual machining unit (12);
a load information determination unit (22) for comparing the virtual load information with the actual load information and determining whether or not there is a difference between these pieces of information;
Equipped with
The simulation unit (14) calculates the virtual load information and comparison point identification data that identifies a comparison point between the virtual load information and the actual load information,
The virtual load acquisition unit (18) acquires the virtual load information in association with the comparison point identification data,
The actual load acquisition unit (16) acquires the actual load information in association with the comparison point identification data,
The load information determination unit (22) compares the virtual load information with the actual load information based on the comparison point specifying data.

(Appendix 2)
In the above processing load judgment system (10),
the comparison point identification data for the actual load information includes at least one of position information or time information of the movable portion (134, 136),
The comparison point specifying data for the virtual load information includes at least one of position information, time information, and the operation data of the virtual moving parts (134s, 136s).

(Appendix 3)
In the above processing load judgment system (10),
The actual load information includes energy generated in the movable parts (134, 136) when the workpiece (W) is machined,
The virtual load information includes energy generated in the virtual moving parts (134s, 136s) when machining the virtual workpiece (Ws).

(Appendix 4)
In the above processing load judgment system (10),
The actual load information is contact information indicating whether or not the tool (T) and the workpiece (W) are in contact with each other,
The virtual load information is contact information indicating whether or not the virtual tool (Ts) and the virtual workpiece (Ws) are in contact with each other.

(Appendix 5)
In the above processing load judgment system (10),
The load information determination unit (22) performs the determination in real time while the actual machining unit (12) is in operation.

(Appendix 6)
In the above processing load judgment system (10),
When the load information determination unit (22) determines that there is a difference between the virtual load information and the actual load information, the actual processing unit (12) performs at least one of limiting the output for operating the movable parts (134, 136), performing a preset retraction operation of the movable parts (134, 136), or immediately decelerating and stopping the operation of the movable parts (134, 136).

(Appendix 7)
In the above processing load judgment system (10),
the simulation unit (14) performs the machining simulation based on the operation data including preconditions related to the virtual tool (Ts), the virtual workpiece (Ws), and the virtual moving part (134s, 136s);
When the load information determination unit (22) determines that there is a difference between the virtual load information and the actual load information, a process in the operation data where there is a difference between these pieces of information is identified based on the comparison point identification data, and a prerequisite for the processing simulation is changed.

(Appendix 8)
In the above processing load judgment system (10),
The actual load information is contact information indicating whether or not the tool (T) and the workpiece (W) are in contact with each other,
the virtual load information is contact information indicating whether or not the virtual tool (Ts) and the virtual workpiece (Ws) are in contact with each other;
The comparison point specifying data for the actual load information includes position information of the movable parts (134, 136),
The comparison point specifying data for the virtual load information includes position information of the virtual moving parts (134s, 136s),
the simulation unit (14) performs the machining simulation based on the operation data including preconditions related to the virtual tool (Ts), the virtual workpiece (Ws), and the virtual moving part (134s, 136s);
when the load information determination unit (22) determines that there is a difference between the virtual load information and the actual load information, a difference is calculated between a machine coordinate at which the tool (t) and the workpiece (W) in the actual machining unit (12) come into contact with each other and a machine coordinate at which the virtual tool (Ts) and the virtual workpiece (Ws) in the simulation unit (14) come into contact with each other;
The difference is used as a correction amount for the virtual tool (Ts) to change the prerequisites for the virtual tool (Ts).

(Appendix 9)
In the above processing load judgment system (10),
The simulation unit (14) performs the machining simulation based on the operation data before the actual machining unit (12) operates, and calculates the comparison location data and the virtual load information.

(Appendix 10)
In the above processing load judgment system (10),
The virtual load acquisition unit (18) writes at least one of the comparison point identification data and the virtual load information in the operation data.

(Appendix 11)
In the above processing load judgment system (10),
The display unit (28) displays, in a different display mode according to the difference, comparison point identification data for which the load information determination unit (22) has determined that there is a difference between the virtual load information and the actual load information.

(Appendix 12)
In the above processing load judgment system (10),
The load information determination unit (22) extracts and compares only the virtual load information and the actual load information for a specific section in the comparison point identification data.

REFERENCE SIGNS LIST 10 Machining load judgment system 12 Actual machining section 14 Simulation section 16 Actual load acquisition section 18 Virtual load acquisition section 20 Storage section 22 Load information judgment section 24 Operation control section 26 Correction section 28 Display section 100 Industrial machinery system 110 Numerical control device 120 Driving section 130 Machine tool (industrial machinery)
132 Motor 134 Mounting part (movable part)
134s Virtual mounting part (virtual moving part)
136 Table (movable part)
136s Virtual table (virtual moving part)
T Tool Ts Virtual tool VS Virtual space W Workpiece (workpiece)
Ws Virtual work (virtual processed part)

Claims (12)

1. an actual machining unit having a movable part on which a tool or a workpiece is provided, and machining the workpiece by relatively moving the tool and the workpiece based on operation data;
   a simulation unit that performs a machining simulation of the virtual workpiece by relatively moving the virtual tool and the virtual workpiece based on the operation data in a virtual space including a virtual tool, a virtual workpiece, and a virtual movable part corresponding to the tool, the workpiece, and the movable part, respectively;
   a virtual load acquisition unit that acquires virtual load information generated on the virtual moving part, the virtual load information being obtained by the machining simulation performed by the simulation unit;
   an actual load acquisition unit that acquires actual load information generated on the movable part, the actual load information being obtained by the processing by the actual processing unit;
   a load information determination unit that compares the virtual load information with the actual load information and determines whether there is a difference between these pieces of information;
   Equipped with
   the simulation unit calculates the virtual load information and comparison point identification data that identifies a comparison point between the virtual load information and the actual load information;
   The virtual load acquisition unit acquires the virtual load information in association with the comparison point identification data,
   The actual load acquisition unit acquires the actual load information in association with the comparison point identification data,
   the load information determination unit compares the virtual load information with the actual load information based on the comparison point identification data;
   Processing load judgment system.
2. the comparison point identification data for the actual load information includes at least one of position information or time information of the movable part,
   The comparison point identification data for the virtual load information includes at least one of position information, time information, or the operation data of the virtual moving part.
   The processing load determination system according to claim 1 .
3. the actual load information includes energy generated in the movable part when the workpiece is machined,
   The virtual load information includes energy generated in the virtual moving part when the virtual workpiece is machined.
   The processing load determination system according to claim 1 or 2.
4. the actual load information is contact information indicating whether or not the tool and the workpiece are in contact with each other,
   the virtual load information is contact information indicating whether or not the virtual tool and the virtual workpiece are in contact with each other;
   The processing load determination system according to claim 1 or 2.
5. The machining load judgment system according to any one of claims 1 to 4, wherein the load information judgment unit performs the judgment in real time while the actual machining unit is operating.
6. The machining load determination system according to any one of claims 1 to 5, wherein, when the load information determination unit determines that there is a difference between the virtual load information and the actual load information, the actual machining unit performs at least one of the following: limiting the output for operating the movable part, performing a preset retraction operation of the movable part, or immediately decelerating and stopping the operation of the movable part.
7. the simulation unit performs the machining simulation based on the operation data including preconditions related to the virtual tool, the virtual workpiece, and the virtual moving part;
   The machining load determination system according to any one of claims 1 to 4, wherein, when the load information determination unit determines that there is a difference between the virtual load information and the actual load information, a process in the operation data where there is a difference between these pieces of information is identified based on the comparison point identification data, and a precondition for the machining simulation is changed.
8. the actual load information is contact information indicating whether or not the tool and the workpiece are in contact with each other,
   the virtual load information is contact information indicating whether or not the virtual tool and the virtual workpiece are in contact with each other,
   the comparison point specifying data for the actual load information includes position information of the movable part,
   the comparison point specifying data for the virtual load information includes position information of the virtual moving part,
   the simulation unit performs the machining simulation based on the operation data including preconditions related to the virtual tool, the virtual workpiece, and the virtual moving part;
   when the load information determination unit determines that there is a difference between the virtual load information and the actual load information, a difference is calculated between a machine coordinate at which the tool and the workpiece in the actual machining unit come into contact with each other and a machine coordinate at which the virtual tool and the virtual workpiece in the simulation unit come into contact with each other;
   changing the prerequisites of the virtual tool using the difference as a correction amount of the virtual tool;
   The processing load determination system according to any one of claims 1 to 4.
9. The machining load judgment system according to any one of claims 1 to 5, wherein the simulation unit performs the machining simulation based on the operation data before the actual machining unit operates, and calculates the comparison point identification data and the virtual load information.
10. The processing load determination system according to claim 2, wherein the virtual load acquisition unit writes at least one of the comparison location identification data and the virtual load information in the operation data.
11. The processing load determination system according to any one of claims 1 to 10, further comprising a display unit that displays, in a different display mode according to the difference, comparison point specific data determined by the load information determination unit to have a difference between the virtual load information and the actual load information.
12. The processing load determination system according to any one of claims 1 to 10, wherein the load information determination unit extracts and compares only the virtual load information and the actual load information for a specific section in the comparison location identification data.

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