WO2024180769A1

WO2024180769A1 - Simulation device and computer-readable storage medium

Info

Publication number: WO2024180769A1
Application number: PCT/JP2023/007856
Authority: WO
Inventors: 小次郎有松; 太郎小木曽
Original assignee: ファナック株式会社
Priority date: 2023-03-02
Filing date: 2023-03-02
Publication date: 2024-09-06

Abstract

This simulation device comprises: a simulation unit that performs an industrial machine operation simulation on the basis of factor information selected by a selection unit; an acquisition unit that acquires result information indicating the results of operating the industrial machine; a determination unit that compares the operation simulation results and the result information to determine whether a defect indicated by the factor information is occurring in the industrial machine; and an output unit that outputs the determination results by the determination unit.

Description

Simulation device and computer-readable storage medium

The present disclosure relates to a simulation device and a computer-readable storage medium.

If an abnormality is confirmed after an industrial machine is in operation, the cause of the abnormality is identified. For example, Patent Document 1 discloses a technology that supports the task of identifying the cause of the abnormality.

Patent No. 7135225

However, even if the technology disclosed in Patent Document 1 is used, it is ultimately up to the operator to determine the cause of the abnormality. Unskilled personnel may not be able to identify the cause of the abnormality due to lack of experience. Therefore, there is a demand for a device that can identify the cause of the abnormality.

The simulation device disclosed herein includes a selection unit that selects factor information indicating the cause of the defect based on operation information indicating the type of operation of the industrial machine and defect information indicating the type of defect that has occurred in the industrial machine, a simulation unit that executes an operation simulation of the industrial machine based on the factor information selected by the selection unit, an acquisition unit that acquires result information indicating the operation result of the industrial machine, a determination unit that compares the result of the operation simulation with the result information to determine whether or not a defect indicated by the factor information has occurred in the industrial machine, and an output unit that outputs the determination result by the determination unit.

The computer-readable storage medium of the present disclosure stores instructions that cause a computer to execute the following: select factor information indicating the cause of a defect based on operation information indicating the type of operation of the industrial machine and defect information indicating the type of defect that occurs in the industrial machine, execute an operation simulation of the industrial machine based on the selected factor information, obtain result information indicating the operation result of the industrial machine, compare the result of the operation simulation with the result information to determine whether or not a defect indicated by the factor information has occurred in the industrial machine, and output the determined result.

FIG. 1 illustrates an example of a system including a simulation device. 1 is a block diagram showing an example of a hardware configuration of an industrial machine; FIG. 2 is a block diagram showing an example of a hardware configuration of the simulation device. FIG. 2 is a block diagram showing an example of a function of the simulation device. FIG. 1 is a diagram illustrating an example of a defect that occurs in an industrial machine. FIG. 1 is a diagram illustrating an example of a defect that occurs in an industrial machine. 4 is a diagram illustrating an example of factor information stored in a factor information storage unit. FIG. FIG. 11 is a diagram showing an example of a result of an operation simulation. FIG. 11 is a diagram illustrating an example of result information acquired by an acquisition unit. FIG. 11 is a diagram showing an example of a display mode of a determination result. 1 is a flowchart showing an example of a flow of a process executed by a simulation device. 4 is a diagram illustrating an example of factor information stored in a factor information storage unit. FIG. FIG. 11 is a diagram showing an example of a result of an operation simulation. FIG. 11 is a diagram illustrating an example of result information acquired by an acquisition unit. FIG. 11 is a diagram showing an example of a display mode of a determination result. 4 is a diagram illustrating an example of factor information stored in a factor information storage unit. FIG. FIG. 11 is a diagram showing an example of a result of an operation simulation. FIG. 11 is a diagram illustrating an example of result information acquired by an acquisition unit. FIG. 11 is a diagram showing an example of a display mode of a determination result.

Below, a simulation device and a computer-readable storage medium according to an embodiment of the present disclosure will be described with reference to the drawings. In the following description, components having the same or similar functions will be given the same reference numerals. Furthermore, duplicate descriptions of those components may be omitted.

In this application, "based on XX" means "based on at least XX," and includes cases where it is based on other elements in addition to XX. Furthermore, "based on XX" is not limited to cases where XX is used directly, but also includes cases where it is based on XX that has been calculated or processed. "XX" is any element (for example, any information).

FIG. 1 is a diagram showing an example of a system including a simulation device of the present disclosure. This system includes an industrial machine 1 and a simulation device 10. The industrial machine 1 and the simulation device 10 are connected by a network N, such as an Internet line or a LAN (Local Area Network).

Industrial machine 1 is a machine that operates in an industrial site. Industrial machine 1 is, for example, a machine tool, an injection molding machine, a laser processing machine, a three-dimensional printer, or a robot.

The simulation device 10 is a device that performs an operation simulation of the industrial machine 1. The operation simulation is, for example, a machining simulation of a machine tool. The operation simulation may also be an operation simulation of a robot. The simulation device 10 is implemented in, for example, a server, a PC (Personal Computer), or a mobile terminal. The simulation device 10 may also be implemented in a numerical control device, which will be described later.

FIG. 2 is a block diagram showing an example of the hardware configuration of the industrial machine 1. The industrial machine 1 includes a numerical control device 2, an input/output device 3, a servo amplifier 4, a servo motor 5, a spindle amplifier 6, a spindle motor 7, an auxiliary device 8, and a measuring instrument 9.

The numerical control device 2 is a device for controlling the industrial machine 1. The numerical control device 2 includes, for example, a hardware processor 201, a bus 202, a ROM (Read Only Memory) 203, a RAM (Random Access Memory) 204, and a non-volatile memory 205.

The hardware processor 201 is a processor that controls the entire numerical control device 2 using a system program. The hardware processor 201 reads out the system program stored in the ROM 203 via the bus 202. The hardware processor 201 is, for example, a CPU (Central Processing Unit) or an electronic circuit.

The bus 202 is a communication path that connects each piece of hardware in the numerical control device 2 to each other. Each piece of hardware in the numerical control device 2 exchanges data via the bus 202.

ROM 203 is a storage device that stores system programs and the like. ROM 203 is a computer-readable storage medium.

RAM 204 is a storage device that temporarily stores various data. RAM 204 functions as a working area for the hardware processor 201 to process various data.

The non-volatile memory 205 is a storage device that retains data even when the power to the numerical control device 2 is turned off. The non-volatile memory 205 stores, for example, the operating program of the industrial machine 1. The non-volatile memory 205 is a computer-readable storage medium. The non-volatile memory 205 is, for example, a battery-backed memory or an SSD (Solid State Drive).

The numerical control device 2 further includes a first interface 206, an axis control circuit 207, a spindle control circuit 208, a PLC (Programmable Logic Controller) 209, an I/O unit 210, a second interface 211, and a third interface 212.

The first interface 206 connects the bus 202 and the input/output device 3. The first interface 206 sends, for example, various data processed by the hardware processor 201 to the input/output device 3.

The input/output device 3 receives various data via the first interface 206 and displays the various data on a display. The input/output device 3 also receives input of various data and sends the various data via the first interface 206 to, for example, the hardware processor 201.

The input/output device 3 is, for example, a touch panel. When the input/output device 3 is a touch panel, the input/output device 3 is, for example, a capacitive touch panel. The touch panel is not limited to a capacitive touch panel, and may be a touch panel of another type. The input/output device 3 is installed in an operation panel (not shown) in which the numerical control device 2 is stored.

The axis control circuit 207 is a circuit for controlling the servo motor 5. The axis control circuit 207 receives control commands from the hardware processor 201 and sends various commands to the servo amplifier 4 for driving the servo motor 5. The axis control circuit 207 sends, for example, a torque command for controlling the torque of the servo motor 5 to the servo amplifier 4.

The servo amplifier 4 receives commands from the axis control circuit 207 and supplies current to the servo motor 5.

The servo motors 5 are driven by receiving a current supply from the servo amplifier 4. The servo motors 5 are provided corresponding to each control axis of the industrial machine 1. If the industrial machine 1 is a machine tool having five axes, the servo motors 5 include, for example, an X-axis servo motor, a Y-axis servo motor, a Z-axis servo motor, an A-axis servo motor, and a C-axis servo motor. In this case, the axis control circuit 207 and the servo amplifier 4 are provided for each servo motor 5.

The servo motor 5 is connected to, for example, a ball screw that moves a structure of the industrial machine 1. When the servo motor 5 is driven, a structure of the industrial machine 1, such as a tool rest, moves along a predetermined control axis.

The servo motor 5 has a built-in encoder (not shown) that detects the position and feed speed of the control axis. Position feedback information and speed feedback information indicating the position of the control axis and the feed speed of the control axis detected by the encoder, respectively, are fed back to the axis control circuit 207. In this way, the axis control circuit 207 performs feedback control of each control axis.

The spindle control circuit 208 is a circuit for controlling the spindle motor 7. The spindle control circuit 208 receives a control command from the hardware processor 201 and sends a command to the spindle amplifier 6 to drive the spindle motor 7. The spindle control circuit 208 sends, for example, a spindle speed command to the spindle amplifier 6 to control the rotation speed of the spindle motor 7.

The spindle amplifier 6 receives commands from the spindle control circuit 208 and supplies current to the spindle motor 7.

The spindle motor 7 is driven by a current supplied from the spindle amplifier 6. The spindle motor 7 is connected to the main shaft and rotates the main shaft.

The PLC 209 is a device that executes a ladder program to control the auxiliary device 8. The PLC 209 sends commands to the auxiliary device 8 via the I/O unit 210.

The I/O unit 210 is an interface that connects the PLC 209 and the auxiliary device 8. The I/O unit 210 sends commands received from the PLC 209 to the auxiliary device 8.

The auxiliary device 8 is installed in the industrial machine 1 and performs auxiliary operations in the industrial machine 1. The auxiliary device 8 operates based on commands received from the I/O unit 210. The auxiliary device 8 may be a device installed in the periphery of the industrial machine 1. The auxiliary device 8 is, for example, a tool changer, a cutting fluid injection device, or an opening/closing door drive device.

The second interface 211 connects the bus 202 and the measuring instrument 9. The second interface 211 sends, for example, measurement data measured by the measuring instrument 9 to the hardware processor 201.

The measuring instrument 9 is a device that measures various physical quantities. The measuring instrument 9 is, for example, an ammeter, a distance measuring sensor, a three-dimensional scanner, and a camera. The ammeter measures, for example, the current supplied to the servo motor 5 and the spindle motor 7. The distance measuring sensor measures, for example, the dimensions of a specific position on the workpiece. The distance measuring sensor includes a touch probe. The camera obtains information such as the shape of the workpiece surface and the presence or absence of scratches.

The third interface 212 connects the bus 202 and the simulation device 10. The third interface 212 sends, for example, measurement data measured by the measuring instrument 9 to the simulation device 10.

FIG. 3 is a block diagram showing an example of the hardware configuration of the simulation device 10. The simulation device 10 includes, for example, a hardware processor 101, a bus 102, a ROM 103, a RAM 104, a non-volatile memory 105, a first interface 106, an input/output device 107, and a second interface 108.

The hardware processor 101 is a processor that controls the entire simulation device 10 in accordance with a system program. The hardware processor 101 reads the system program and the like stored in the ROM 103 via the bus 102. The hardware processor 101 is, for example, a CPU or an electronic circuit.

The bus 102 is a communication path that connects each piece of hardware in the simulation device 10 to each other. Each piece of hardware in the simulation device 10 exchanges data via the bus 102.

ROM 103 is a storage device that stores system programs and the like. ROM 103 is a computer-readable storage medium.

RAM 104 is a storage device that temporarily stores various data. RAM 104 functions as a working area for the hardware processor 101 to process various data.

The non-volatile memory 105 is a storage device that retains data even when the power to the simulation device 10 is turned off. The non-volatile memory 105 stores, for example, a simulation program. The non-volatile memory 105 is a computer-readable storage medium. The non-volatile memory 105 is, for example, a battery-backed memory or an SSD.

The first interface 106 connects the bus 102 and the input/output device 107. The first interface 106 sends, for example, various data processed by the hardware processor 101 to the input/output device 107.

The input/output device 107 receives various data via the first interface 106 and displays the various data on a display. The input/output device 107 also receives input of various data and sends the various data via the first interface 106 to, for example, the hardware processor 101.

The input/output device 107 is, for example, a touch panel. When the input/output device 107 is a touch panel, the input/output device 107 is, for example, a capacitive touch panel. The touch panel is not limited to a capacitive touch panel, and may be a touch panel of another type.

The second interface 108 connects the bus 102 and the numerical control device 2. The second interface 108 receives, for example, measurement data measured by the measuring instrument 9 of the industrial machine 1 and sends the data to the non-volatile memory 105.

FIG. 4 is a block diagram showing an example of the functions of the simulation device 10. The simulation device 10 includes, for example, an information receiving unit 111, a factor information storage unit 112, a selection unit 113, a model storage unit 114, a simulation unit 115, an acquisition unit 116, a determination unit 117, a correction unit 118, and an output unit 119.

The information receiving unit 111, the selection unit 113, the simulation unit 115, the acquisition unit 116, the determination unit 117, the correction unit 118 and the output unit 119 are realized, for example, by the hardware processor 101 performing calculations using the system program stored in the ROM 103 and various data stored in the non-volatile memory 105.

The factor information storage unit 112 is realized, for example, by storing factor information indicating defective factors in the non-volatile memory 105. The model storage unit 114 is realized, for example, by storing data of various virtual models in the non-volatile memory 105.

The information receiving unit 111 receives operation information indicating the type of operation of the industrial machine 1 and defect information indicating the type of defect that has occurred in the industrial machine 1. The type of operation is, for example, the type of machining. The type of machining includes, for example, hole drilling and milling. The type of defect includes, for example, shape distortion, scratches on the machined surface due to unstable rotation speed, and dimensional errors.

The information receiving unit 111, for example, displays an image showing the operational information and an image showing the defect information stored in a storage unit (not shown) on the display of the input/output device 107 and receives an operation of selecting these images by the operator. This allows the information receiving unit 111 to receive the operational information and the defect information.

The information receiving unit 111 may also obtain operation information from an operation program. The information receiving unit 111 may also obtain defect information from a measuring instrument 9.

FIGS. 5A and 5B are diagrams illustrating an example of a defect that occurs in industrial machine 1. In the example shown in FIGS. 5A and 5B, industrial machine 1 performs machining using polar coordinate interpolation around the Z axis. Polar coordinate interpolation around the Z axis is a function that synchronizes the linear axis (X axis) and the rotational axis (C axis) and converts commands programmed in a Cartesian coordinate system into linear axis movement (tool movement) and rotational axis movement (workpiece rotation) to perform contour control. Polar coordinate interpolation is used, for example, in machining to cut the cross section of workpiece W into a polygon (a rectangle in FIGS. 5A and 5B).

In FIG. 5A, each face that constitutes a polygon parallel to the Z axis is machined to be almost flat. In other words, no defects have occurred in the industrial machine 1.

On the other hand, in FIG. 5B, distortion has occurred on each face that constitutes the polygon. In other words, there is a possibility that a defect has occurred in the industrial machine 1. In this case, the information receiving unit 111 receives operation information indicating that polar coordinate interpolation is being performed, and defect information indicating that a distortion of the shape has occurred.

The factor information storage unit 112 stores factor information indicating the factors of defects. A defect factor is a cause that causes a defect. The factor information includes, for example, a numerical value indicating the rigidity of the industrial machine 1, a numerical value indicating the coefficient of friction when a structure constituting the industrial machine 1 operates, a numerical value indicating the geometric error of a structure constituting the industrial machine 1, and a numerical value indicating the amount of wear of a tool. A geometric error is an error related to the positional relationship of the drive shaft, which affects the operating accuracy of the industrial machine 1.

FIG. 6 is a diagram showing an example of factor information stored in the factor information storage unit 112. Defective factors indicated by the factor information include, for example, "Y-direction error of the C-axis center" and "eccentricity of the rotation axis." "Y-direction error of the C-axis center" is a type of geometric error, and means that there is a deviation in the Y direction between the coordinate setting of the C-axis center and the actual position of the C-axis center, as shown in FIG. 5B.

"Eccentricity of the rotation axis" means that the workpiece W is fixed to the chuck away from the center of the rotation axis.

The factor information may include a numerical value indicating the degree of defect. The numerical value indicating the degree of defect may include, for example, a numerical value indicating the rigidity of the industrial machine 1, a numerical value indicating the coefficient of friction, a numerical value indicating the geometric error, and a numerical value indicating the amount of wear of the tool.

The factor information storage unit 112 stores factor information in association with operation information and defect information. In other words, the factor information storage unit 112 stores defects that may occur when the industrial machine 1 performs a specific operation in association with the causes of the defects.

The factor information storage unit 112 stores "Y direction error at the center of the C axis" in association with "polar coordinate interpolation" and "shape distortion." The factor information storage unit 112 also stores "eccentricity of the rotation axis" in association with "polar coordinate interpolation" and "shape distortion." Now, let us return to the explanation of Figure 4.

The selection unit 113 selects factor information indicating the cause of a defect based on operation information indicating the type of operation of the industrial machine 1 and defect information indicating the type of defect occurring in the industrial machine 1. The selection unit 113 selects at least one piece of factor information from the multiple pieces of factor information stored in the factor information storage unit 112.

For example, if the information receiving unit 111 receives operation information indicating "polar coordinate interpolation" and defect information indicating "shape distortion", the selection unit 113 selects "Y direction error from the center of the C axis" as the factor information. If the information receiving unit 111 receives operation information indicating "polar coordinate interpolation" and defect information indicating "shape distortion", the selection unit 113 may select "eccentricity of the rotation axis" as the factor information.

The model storage unit 114 stores a virtual model of the industrial machine 1. The virtual model of the industrial machine 1 includes a structure model, which is a virtual model of each structure of the industrial machine 1, a numerical control model, which is a virtual model of the numerical control device 2 that controls the industrial machine 1, and a work model, which is a virtual model of the workpiece W.

The numerical control model performs a simulation of the operation of the industrial machine 1 by operating the structure model.

The structure model includes, for example, a virtual model of the drive shaft, a virtual model of the bed, a virtual model of the drive shaft head, a virtual model of the column, a virtual model of the linear guide, a virtual model of the bearing, a virtual model of the tool, a virtual model of the motor, and a virtual model of the cutting fluid injection device. The structure model also includes information indicating, for example, the shape, weight, material, friction coefficient, rigidity, heat capacity, thermal conductivity, and longitudinal elastic modulus of the structure.

The virtual model of the motor obtains virtual feedback information by driving the virtual model of the drive shaft. The virtual model of the motor includes information about the specifications of the motor. The information about the specifications includes, for example, information indicating the rated torque, rated output, rated rotational speed, maximum torque, maximum rotational speed, and encoder resolution.

The workpiece model includes information indicating, for example, the shape, weight, material, rigidity, heat capacity, thermal conductivity, and modulus of longitudinal elasticity of the workpiece W.

The simulation unit 115 executes an operation simulation of the industrial machine 1 based on the factor information selected by the selection unit 113. The simulation unit 115 executes the operation simulation using a virtual model of the industrial machine 1. The simulation unit 115 executes the operation simulation using an operation program.

For example, if the selection unit 113 selects "Y direction error of the C-axis center," the simulation unit 115 shifts the Y direction position of the C-axis center in the virtual model and performs an operational simulation.

If the factor information includes a numerical value indicating the Y-direction error around the C-axis, the simulation unit 115 executes the operation simulation by shifting the Y-direction position of the C-axis center by the numerical value indicating the Y-direction error around the C-axis center. For example, if the factor information includes a numerical value of 0.3 mm indicating the Y-direction error around the C-axis center, the simulation unit 115 executes the operation simulation by shifting the Y-direction position of the C-axis center by 0.3 mm.

The simulation unit 115 executes an operation simulation to obtain the results of the operation simulation. Information indicating the operation simulation results includes, for example, information indicating the shape of the workpiece W or information indicating the dimensions of the workpiece W.

FIG. 7 shows an example of the results of an operation simulation. The simulation unit 115 obtains information indicating the shape of the workpiece W when the operation simulation is performed with the deviation amount in the Y direction from the center of the C axis set to 0.3 mm.

The acquisition unit 116 acquires result information indicating the operation results of the industrial machine 1, for example, from the measuring instrument 9. The result information indicating the operation results includes, for example, operation status information indicating the state when the industrial machine 1 is operating based on the operation program, or work status information indicating the state of the machined workpiece W.

The operating status information includes, for example, information indicating the torque of the servo motor 5 when the industrial machine 1 is operating, or information indicating the torque of the spindle motor 7 when the industrial machine 1 is operating. The operating status information is time-series data. The work status information is information indicating the measurement results such as the shape, dimensions, surface roughness, or the presence or absence of scratches of the machined workpiece W.

FIG. 8 is a diagram showing an example of result information acquired by the acquisition unit 116. The result information is image data captured by a camera. The image data may include data indicating the dimensions of each part of the workpiece W after machining. Now, we return to the explanation of FIG. 4.

The determination unit 117 compares the results of the operation simulation with result information indicating the operation results of the industrial machine 1 to determine whether or not a defect indicated by the factor information has occurred in the industrial machine 1. The determination unit 117, for example, compares the shape of the workpiece W indicated by the result information with the shape of the workpiece W obtained by executing the operation simulation.

In the examples shown in Figures 7 and 8, the determination unit 117 determines that the shape of the workpiece W obtained by executing the operation simulation does not match the shape of the workpiece W indicated by the operation results acquired by the acquisition unit 116. Therefore, the determination unit 117 determines that the defect indicated by the factor information has not occurred.

If the determination unit 117 determines that no defect indicated by the factor information has occurred, the correction unit 118 corrects the factor information selected by the selection unit 113.

The correction of the factor information involves, for example, changing the numerical values that indicate the degree of defect contained in the factor information. The numerical values that indicate the degree of defect include a numerical value that indicates the rigidity of each structure of the industrial machinery 1, a numerical value that indicates the coefficient of friction when each structure of the industrial machinery 1 operates, a numerical value that indicates the geometric error of each structure of the industrial machinery 1, and a numerical value that indicates the amount of wear on the tools.

When the correction unit 118 has performed a correction, the selection unit 113 selects the factor information after the correction. For example, when the correction unit 118 changes the value indicating the Y-direction error from the center of the C-axis from 0.3 [mm] to 0.4 [mm], the selection unit 113 selects the changed value of 0.4 [mm]. In this case, the simulation unit 115 again performs an operation simulation of the industrial machine 1 based on the factor information selected by the selection unit 113.

If the determination unit 117 again determines that the defect indicated by the factor information has not occurred, the correction unit 118 further changes the value indicating the Y-direction error from the center of the C-axis from 0.4 mm to 0.5 mm.

The correction of factor information may involve changing the factor information selected by the selection unit 113 to other factor information. For example, as shown in FIG. 6, the factor information storage unit 112 stores "eccentricity of rotation axis" in association with "polar coordinate interpolation" and "shape distortion." Therefore, the correction unit 118 may change the factor information from "Y-direction error of the center of the C-axis" to "eccentricity of the rotation axis."

The output unit 119 outputs the judgment result by the judgment unit 117. The output unit 119 outputs the judgment result, for example, to the input/output device 107. If the judgment unit 117 judges that, for example, a Y-direction error has occurred about the C-axis, the output unit 119 outputs a judgment result indicating that a Y-direction error has occurred about the C-axis to the input/output device 107. The output unit 119 may further output a numerical value indicating the degree of defect.

FIG. 9 is a diagram showing an example of the display mode of the judgment result. When the correction unit 118 changes the Y direction error from the center of the C axis from 0.3 mm to 0.4 mm, and from 0.4 mm to 0.5 mm in that order, the output unit 119 outputs to the input/output device 107 the shapes of each workpiece W obtained by executing the operation simulation. The output unit 119 also outputs to the input/output device 107 a numerical value indicating the degree of defect that is set when the result of the operation simulation matches the result information indicating the operation result of the industrial machine 1. In FIG. 9, an arrow indicates that when the Y direction error from the center of the C axis is set to 0.5 mm, the result of the operation simulation matches the result information.

The determination unit 117 may count the number of times that it has determined that the defect indicated by the factor information has not occurred in the industrial machine 1. For example, if the determination unit 117 determines that the defect indicated by the factor information has not occurred a predetermined number of times, the output unit 119 outputs a determination result indicating that the defect factor could not be identified.

FIG. 10 is a flowchart showing an example of the flow of processing executed by the simulation device 10. In the simulation device 10, first, the information receiving unit 111 receives operation information indicating the type of operation of the industrial machine 1 and defect information indicating the type of defect that has occurred in the industrial machine 1 (step S1). That is, the information receiving unit 111 receives the operation information and defect information after an operation is performed in the industrial machine 1.

Next, the selection unit 113 selects factor information indicating the cause of the defect based on the operation information and the defect information (step S2).

Next, the simulation unit 115 performs an operation simulation using a virtual model of the industrial machine 1 based on the factor information selected by the selection unit 113 (step S3).

Next, the acquisition unit 116 acquires result information indicating the operation results of the industrial machine 1 (step S4).

Next, the judgment unit 117 compares the results of the operation simulation with the result information indicating the operation results of the industrial machine 1 to judge whether or not a defect indicated by the factor information has occurred in the industrial machine 1 (step S5).

If the judgment unit 117 judges that a defect indicated by the factor information has occurred (Yes in step S5), the output unit 119 outputs the judgment result by the judgment unit 117 (step S6), and the process ends.

If the judgment unit 117 judges that the defect indicated by the factor information has not occurred (No in step S5), the judgment unit 117 judges whether or not it has been judged that the defect has not occurred more than a predetermined number of times (step S7).

If the number of times that it is determined that no defect has occurred exceeds a predetermined number (Yes in step S7), the output unit 119 outputs a determination result indicating that the cause of the defect cannot be identified (step S6), and the process ends. On the other hand, if the number of times that it is determined that no defect has occurred is equal to or less than the predetermined number (No in step S7), the correction unit 118 corrects the factor information (step S8).

Then, the selection unit 113 selects the factor information corrected by the correction unit 118 (step S2), and the processing continues from step S3 onwards.

Next, an example of a case where hole drilling is performed will be described. There are cases where the rotation of the spindle is unstable while the industrial machine 1 is performing hole drilling, and the operator discovers that the machined surface has been scratched after the hole drilling. In this case, the operator inputs to the simulation device 10 operation information indicating that hole drilling has been performed, and defect information indicating that the rotation of the spindle is unstable and that the machined surface has been scratched.

In this case, the information receiving unit 111 receives operation information indicating that hole machining has been performed, and defect information indicating that the rotation of the spindle is unstable and that the machined surface has been scratched.

FIG. 11 is a diagram showing an example of factor information stored in the factor information storage unit 112. Defective factors indicated by the factor information include, for example, "decreased spindle stiffness" and "decreased feed shaft stiffness." "Decreased spindle stiffness" means a decrease in stiffness of the spindle and the parts surrounding the spindle. The parts surrounding the spindle include the bearings that grip the spindle. Also, a decrease in spindle stiffness includes increased runout of the spindle due to wear or damage to the bearings.

"Decrease in feed axis rigidity" means a decrease in the rigidity of the structure that constitutes the feed axis. For example, the feed axis rigidity decreases when the linear guide and ball screw that constitute the feed axis become worn or damaged.

The factor information may include a numerical value indicating the rigidity of the spindle or the rigidity of the feed shaft as a numerical value indicating the degree of defect.

The factor information storage unit 112 stores factor information in association with operation information and defect information. For example, the factor information storage unit 112 stores "reduction in spindle rigidity" in association with "hole machining" and "unstable rotation, scratches on the machining surface." The factor information storage unit 112 also stores "reduction in feed axis rigidity" in association with "hole machining" and "unstable rotation, scratches on the machining surface."

The selection unit 113 selects factor information indicating the cause of the defect based on operation information indicating the type of operation of the industrial machine 1 and defect information indicating the type of defect that has occurred in the industrial machine 1.

For example, if the information receiving unit 111 receives operation information indicating "hole drilling" and defect information indicating "unstable rotation, scratches on the machined surface," the selection unit 113 selects "decreased spindle rigidity" as the factor information. If the information receiving unit 111 receives operation information indicating "hole drilling" and defect information indicating "unstable rotation, scratches on the machined surface," the selection unit 113 may select "decreased feed axis rigidity" as the factor information.

The simulation unit 115 executes an operation simulation of the industrial machine 1 based on the factor information selected by the selection unit 113. The simulation unit 115 executes the operation simulation using a virtual model of the industrial machine 1. The simulation unit 115 executes the operation simulation by setting the stiffness of the main shaft in the virtual model to a predetermined first value.

The simulation unit 115 executes an operation simulation to obtain the results of the operation simulation. Information indicating the results of the operation simulation includes, for example, information indicating the torque of the servo motor 5 or information indicating the torque of the spindle motor 7.

FIG. 12 is a diagram showing an example of the results of an operation simulation. The simulation unit 115 obtains information indicating the torque of the spindle motor 7 when an operation simulation is performed with the stiffness of the spindle set to a predetermined first value in the virtual model. The information indicating the torque is a torque waveform.

The acquisition unit 116 acquires result information indicating the operation result of the industrial machine 1, for example, from the measuring instrument 9. The information indicating the operation result is information indicating the torque of the spindle motor 7 when the industrial machine 1 is operating based on the operation program.

FIG. 13 is a diagram showing an example of result information acquired by the acquisition unit 116. The result information is information indicating the torque of the spindle motor 7 acquired from the spindle amplifier 6 while the industrial machine 1 is in operation.

The determination unit 117 compares the results of the operation simulation with result information indicating the operation results of the industrial machine 1 to determine whether or not a defect indicated by the factor information has occurred in the industrial machine 1. The determination unit 117, for example, compares the torque waveform indicated by the result information with the torque waveform obtained by executing the operation simulation.

In the examples shown in Figures 12 and 13, the determination unit 117 determines that the torque waveform obtained by executing the operation simulation does not match the torque waveform indicated by the operation result. Therefore, the determination unit 117 determines that the defect indicated by the factor information has not occurred.

In this case, the correction unit 118 corrects the factor information selected by the selection unit 113. The correction unit 118 changes the numerical value indicating the stiffness of the spindle from a first value to a second value.

When the correction unit 118 has performed a correction, the selection unit 113 selects the factor information after the correction. When the correction unit 118 has changed the numerical value indicating the stiffness of the main shaft from a first value to a second value, the selection unit 113 selects the second value. In this case, the simulation unit 115 again performs an operation simulation of the industrial machine 1 based on the second value selected by the selection unit 113.

Furthermore, if the determination unit 117 again determines that the defect indicated by the factor information has not occurred, the correction unit 118 changes, for example, the numerical value indicating the stiffness of the spindle from the second value to a third value.

The correction of factor information may involve changing the factor information selected by the selection unit 113 to other factor information. For example, as shown in FIG. 11, the factor information storage unit 112 stores "decreased feed shaft stiffness" in association with "hole machining" and "unstable rotation, scratches on the machining surface." Therefore, the correction unit 118 may change the factor information from "decreased spindle stiffness" to "decreased feed shaft stiffness."

The output unit 119 outputs the result of the determination made by the determination unit 117. If the determination unit 117 determines that, for example, a "decrease in spindle stiffness" has occurred, the output unit 119 outputs a determination result indicating that a decrease in spindle stiffness has occurred to the input/output device 107. The output unit 119 may further output a numerical value indicating the degree of defect.

FIG. 14 is a diagram showing an example of a display mode of the judgment result. When the value indicating the stiffness of the spindle is changed by the correction unit 118 from a first value to a second value and from the second value to a third value in that order, the output unit 119 causes the input/output device 107 to display each of the torque waveforms obtained by executing the operation simulation. In addition, the output unit 119 outputs to the input/output device 107 a numerical value indicating the degree of defect that is set when the result of the operation simulation matches the result information indicating the operation result of the industrial machine 1. FIG. 14 shows by an arrow that when the value indicating the stiffness of the spindle is set to the third value, the result of the operation simulation matches the result information.

Next, an example of a case where milling is performed will be described. After the industrial machine 1 mills the surface of the workpiece W, the operator may discover that a dimensional error has occurred in the height of the machined surface. In this case, the operator inputs to the simulation device 10 operation information indicating that milling has been performed and defect information indicating that a dimensional error has occurred.

In this case, the information receiving unit 111 receives operation information indicating that milling has been performed, and defect information indicating that a dimensional error has occurred.

FIG. 15 is a diagram showing an example of factor information stored in the factor information storage unit 112. Defective factors indicated by the factor information include, for example, "tool wear," "reduction in spindle rigidity," and "coordinate system deviation." "Coordinate system deviation" means that the position of the origin of the work coordinate system is deviated from the position where it should be set.

The factor information may include a numerical value indicating the degree of defect, such as a numerical value indicating the amount of wear on the tool, a numerical value indicating the rigidity of the spindle, or a numerical value indicating the amount of deviation in the coordinate system.

The factor information storage unit 112 stores factor information in association with operation information and defect information. For example, the factor information storage unit 112 stores "tool wear" in association with "milling" and "dimensional error". The factor information storage unit 112 also stores "reduction in spindle rigidity" in association with "milling" and "dimensional error". The factor information storage unit 112 also stores "coordinate system deviation" in association with "milling" and "dimensional error".

For example, if the information receiving unit 111 receives operation information indicating "milling" and defect information indicating "dimensional error", the selection unit 113 selects "tool wear" as the factor information. If the information receiving unit 111 receives operation information indicating "milling" and defect information indicating "dimensional error", the selection unit 113 may select "reduction in spindle rigidity" as the factor information. If the information receiving unit 111 receives operation information indicating "milling" and defect information indicating "dimensional error", the selection unit 113 may select "misalignment of the coordinate system" as the factor information.

The simulation unit 115 executes an operation simulation using a virtual model of the industrial machine 1 based on the factor information selected by the selection unit 113. The simulation unit 115 executes the operation simulation by setting the amount of tool wear in the virtual model to, for example, 0.1 mm.

The simulation unit 115 executes an operation simulation to obtain the results of the operation simulation. The information indicating the results of the operation simulation includes, for example, information indicating the dimensions of the workpiece W. The dimensions of the workpiece W may include, for example, the height of the machined surface of the workpiece W and the depth of the machined hole.

FIG. 16 is a diagram showing an example of the results of an operational simulation. The simulation unit 115 sets the wear amount of the milling tool to, for example, 0.1 mm, and obtains information indicating the results of the operational simulation.

The acquisition unit 116 acquires result information indicating the operation results of the industrial machine 1, for example, from the measuring device 9. The result information indicating the operation results is information indicating the height of the surface of the workpiece W machined based on the operation program.

FIG. 17 is a diagram showing an example of result information acquired by the acquisition unit 116. The result information is, for example, an image of the workpiece W measured by a 3D scanner and information indicating the height of the surface of the workpiece W.

The determination unit 117 compares the results of the operation simulation with result information indicating the operation results of the industrial machine 1 to determine whether or not a defect indicated by the factor information has occurred in the industrial machine 1. The determination unit 117, for example, compares the height of the surface of the workpiece W indicated by the result information with the height of the surface of the workpiece W obtained by executing the operation simulation.

In the example shown in Figures 16 and 17, the determination unit 117 determines that the surface height of the workpiece W obtained by executing the operation simulation matches the surface height of the workpiece W indicated by the operation result acquired by the acquisition unit 116.

The output unit 119 outputs the determination result by the determination unit 117. When the determination unit 117 determines that the surface height of the workpiece W obtained by executing the operation simulation matches the surface height of the workpiece W indicated by the operation result, the output unit 119 outputs to the input/output device 107 a determination result indicating that tool wear is occurring.

FIG. 18 is a diagram showing an example of a display mode of the judgment result. The output unit 119 causes the input/output device 107 to display the shape of the workpiece W obtained by executing the operation simulation. In addition, the output unit 119 outputs to the input/output device 107 a numerical value indicating the degree of defect that is set when the result of the operation simulation matches the result information indicating the operation result of the industrial machine 1. In FIG. 18, an arrow indicates that the result of the operation simulation matches the result information when the amount of tool wear is set to 0.1 [mm].

In the above-described embodiment, only when the determination unit 117 determines that no defect indicated by the factor information has occurred, the correction unit 118 corrects the factor information and performs the operation simulation again.

However, after the simulation unit 115 executes multiple operational simulations in succession, the determination unit 117 may determine whether the results of the multiple operational simulations match the result information acquired by the acquisition unit 116.

For example, in the example where the polar coordinate interpolation described above is performed, the simulation unit 115 sets the numerical value indicating the Y-direction error from the center of the C-axis to 0.3 [mm], 0.4 [mm], and 0.5 [mm] and executes multiple operation simulations. After that, the determination unit 117 compares the results of each operation simulation with the result information acquired by the acquisition unit 116. In other words, the determination unit 117 determines which operation simulation result the result information acquired by the acquisition unit 116 matches.

In this case, the determination unit 117 may determine that the result of the operation simulation that is most similar to the result information acquired by the acquisition unit 116 is the result of the operation simulation that matches the result information.

In the above-described embodiment, as shown in FIG. 9, FIG. 14, and FIG. 18, the simulation device 10 identifies the cause of one abnormality. However, the simulation device 10 may identify the causes of two or more abnormalities.

For example, in the example shown in FIG. 6, the selection unit 113 selects "Y-direction error from the center of the C-axis" and "eccentricity of the rotation axis" as the factor information. In this case, the simulation unit 115 executes the operation simulation by changing the numerical values indicating the degree of defect contained in each of "Y-direction error from the center of the C-axis" and "eccentricity of the rotation axis" multiple times.

For example, the simulation unit 115 first executes an operation simulation by setting the value indicating the degree of eccentricity of the rotation axis to -0.1 [mm] and the Y direction error around the C axis to 0.3 [mm]. Next, the simulation unit 115 executes an operation simulation by setting the value indicating the degree of eccentricity of the rotation axis to -0.1 [mm] and the Y direction error around the C axis to 0.4 [mm]. Next, the simulation unit 115 executes an operation simulation by setting the value indicating the degree of eccentricity of the rotation axis to -0.1 [mm] and the Y direction error around the C axis to 0.5 [mm].

Then, the simulation unit 115 sets the value indicating the degree of eccentricity of the rotating shaft to 0.1 [mm] and the Y direction error around the C axis to 0.3 [mm], and executes an operation simulation. The simulation unit 115 then sets the value indicating the degree of eccentricity of the rotating shaft to 0.1 [mm] and the Y direction error around the C axis to 0.4 [mm], and executes an operation simulation. The simulation unit 115 then sets the value indicating the degree of eccentricity of the rotating shaft to 0.1 [mm] and the Y direction error around the C axis to 0.5 [mm], and executes an operation simulation.

As a result, even if there are multiple causes of an abnormality, the simulation device 10 can identify the causes of those multiple abnormalities.

As described above, the simulation device 10 includes a selection unit 113 that selects factor information indicating the cause of a defect based on operation information indicating the type of operation of the industrial machine 1 and defect information indicating the type of defect occurring in the industrial machine 1, a simulation unit 115 that executes an operation simulation of the industrial machine 1 based on the factor information selected by the selection unit 113, an acquisition unit 116 that acquires result information indicating the operation result of the industrial machine 1, a determination unit 117 that compares the result of the operation simulation with the result information to determine whether or not a defect indicated by the factor information has occurred in the industrial machine 1, and an output unit 119 that outputs the determination result by the determination unit 117.

The computer-readable storage medium also stores instructions that cause the computer to execute the following: select factor information indicating the cause of the defect based on operation information indicating the type of operation of the industrial machine 1 and defect information indicating the type of defect that occurs in the industrial machine 1; execute an operation simulation of the industrial machine 1 based on the selected factor information; obtain result information indicating the operation result of the industrial machine 1; compare the result of the operation simulation with the result information to determine whether or not a defect indicated by the factor information has occurred in the industrial machine 1; and output the determined result.

Therefore, the simulation device 10 can identify the cause of the abnormality in the industrial machine 1.

The factor information includes at least one of a numerical value indicating the rigidity of the industrial machine 1, a numerical value indicating the coefficient of friction, a numerical value indicating the geometric error, and a numerical value indicating the amount of wear of the tool. The simulation device 10 further includes a correction unit 118 that corrects the factor information selected by the selection unit 113 when it is determined that the defect indicated by the factor information has not occurred. When the determination unit 117 determines that the defect has not occurred more than a predetermined number of times, the output unit 119 outputs a determination result indicating that the defect factor cannot be identified. The simulation unit 115 also executes an operation simulation using a virtual model of the industrial machine 1. Therefore, the simulation device 10 can reliably identify the cause of an abnormality that is actually occurring in the industrial machine 1. The simulation device 10 can also prevent the operation simulation from being repeated more than a predetermined number of times.

In addition, the information indicating the operation results includes operation status information indicating the state when the industrial machine 1 is operating based on the operation program, or work status information indicating the state of the machined workpiece W. The operation status information includes information indicating the torque of the servo motor 5 when the industrial machine 1 is operating, or information indicating the torque of the spindle motor 7 when the industrial machine 1 is operating. The work status information includes information indicating the measurement results of the shape, dimensions, surface roughness, or presence or absence of scratches on the machined workpiece W. Therefore, the simulation device 10 can identify the causes of various abnormalities that occur in the industrial machine 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 gist of the present disclosure derived from the contents described in the claims and their equivalents. These embodiments can also be implemented in combination.

Below, notes relating to embodiments of the present disclosure are provided.
Appendix [1]
a simulation unit that executes an operation simulation of the industrial machine based on the factor information selected by the selection unit; an acquisition unit that acquires result information that indicates an operation result of the industrial machine; a determination unit that compares a result of the operation simulation with the result information to determine whether or not the defect indicated by the factor information has occurred in the industrial machine; and an output unit that outputs a result of the determination made by the determination unit.
Appendix [2]
The simulation device according to claim 1, wherein the factor information includes at least one of a numerical value indicating a rigidity of the industrial machine, a numerical value indicating a coefficient of friction, a numerical value indicating a geometric error, and a numerical value indicating an amount of wear of a tool.
Appendix [3]
The simulation apparatus according to claim 1, further comprising a correction unit that corrects the factor information selected by the selection unit when it is determined that the failure indicated by the factor information has not occurred.
Appendix [4]
The simulation device according to claim 3, wherein, when the judgment unit judges that the defect has not occurred a predetermined number of times or more, the output unit outputs a judgment result indicating that a cause of the defect cannot be identified.
Appendix [5]
The simulation device according to any one of appendices [1] to [4], wherein the simulation unit executes the operation simulation using a virtual model of the industrial machine.
Appendix [6]
The simulation device according to any one of appendices [1] to [5], wherein the result information indicating the operation result includes operation status information indicating a state when the industrial machine is operating based on an operation program, or work status information indicating a state of a machined workpiece.
Appendix [7]
The simulation device according to claim 6, wherein the operating state information is information indicating a torque of a servo motor when the industrial machine is operating, or information indicating a torque of a spindle motor when the industrial machine is operating.
Appendix [8]
The simulation device according to claim 6, wherein the workpiece condition information is information indicating measurement results of the shape, dimensions, surface roughness, or presence or absence of scratches of the machined workpiece.
Appendix [9]
A computer-readable storage medium storing instructions to cause a computer to execute the following: selecting factor information indicating a factor of a defect based on operation information indicating a type of operation of an industrial machine and defect information indicating a type of defect occurring in the industrial machine; executing an operation simulation of the industrial machine based on the selected factor information; obtaining result information indicating an operation result of the industrial machine; comparing a result of the operation simulation with the result information to determine whether or not the defect indicated by the factor information has occurred in the industrial machine; and outputting the determined result.

Reference Signs List 1 Industrial machine 2 Numerical control device 201 Hardware processor 202 Bus 203 ROM
204 RAM
205 Non-volatile memory 206 First interface 207 Axis control circuit 208 Spindle control circuit 209 PLC
210 I/O unit 211 Second interface 212 Third interface 3 Input/output device 4 Servo amplifier 5 Servo motor 6 Spindle amplifier 7 Spindle motor 8 Auxiliary device 9 Measuring instrument 10 Simulation device 101 Hardware processor 102 Bus 103 ROM
104 RAM
REFERENCE SIGNS LIST 105 Non-volatile memory 106 First interface 107 Input/output device 108 Second interface 111 Information receiving section 112 Factor information storage section 113 Selection section 114 Model storage section 115 Simulation section 116 Acquisition section 117 Determination section 118 Correction section 119 Output section

Claims

a selection unit that selects factor information indicating a factor of the defect based on operation information indicating a type of operation of the industrial machine and defect information indicating a type of defect occurring in the industrial machine;
a simulation unit that executes an operation simulation of the industrial machine based on the factor information selected by the selection unit;
an acquisition unit that acquires result information indicating an operation result of the industrial machine;
a determination unit that compares a result of the operation simulation with the result information to determine whether or not the defect indicated by the factor information has occurred in the industrial machine;
an output unit that outputs a determination result by the determination unit;
A simulation device comprising:
The simulation device according to claim 1, wherein the factor information includes at least one of a numerical value indicating the rigidity of the industrial machine, a numerical value indicating the coefficient of friction, a numerical value indicating a geometric error, and a numerical value indicating the amount of wear of a tool.
The simulation device according to claim 1 or 2, further comprising a correction unit that corrects the factor information selected by the selection unit when it is determined that the defect indicated by the factor information has not occurred.
The simulation device according to claim 3, wherein if the determination unit determines that the defect has not occurred a predetermined number of times, the output unit outputs a determination result indicating that the cause of the defect cannot be identified.
The simulation device according to any one of claims 1 to 4, wherein the simulation unit executes the operation simulation using a virtual model of the industrial machine.
The simulation device according to any one of claims 1 to 5, wherein the result information indicating the operation result includes operation status information indicating the state when the industrial machine is operating based on an operation program, or work status information indicating the state of a machined workpiece.
The simulation device according to claim 6, wherein the operating state information is information indicating the torque of a servo motor when the industrial machine is operating, or information indicating the torque of a spindle motor when the industrial machine is operating.
The simulation device according to claim 6, wherein the workpiece condition information is information indicating the measurement results of the shape, dimensions, surface roughness, or presence or absence of scratches of the machined workpiece.
selecting factor information indicating a factor of the defect based on operation information indicating a type of operation of the industrial machine and defect information indicating a type of defect occurring in the industrial machine;
executing an operation simulation of the industrial machine based on the selected factor information;
Obtaining result information indicating an operation result of the industrial machine;
comparing a result of the operation simulation with the result information to determine whether or not the defect indicated by the factor information has occurred in the industrial machine;
Outputting the determined result; and
A computer-readable storage medium that stores instructions for causing a computer to execute the above.