DESCRIPTION OF THE PREFERRED EMBODIMENT

[0028] With reference to the attached drawings, the present invention will hereinafter be described by way of a specific embodiment thereof. FIG. 1 is a block diagram illustrating the major construction of a numerical controller according to the embodiment of the present invention.

[0029] As shown, the numerical controller 1 according to this embodiment includes processing sections such as a configuration data generating section 3 , a process/machining model data generating section 5 , a tool/machining condition database updating section 7 , a machining-related information generating section 10 , a machining-related information rewriting section 13 , a motion data generating section 14 and an NC machining program generating section 16 , storage sections such as a CAD data storage section 2 , a configuration data storage section 4 , a process/machining model data storage section 6 , a tool database 8 , a machining condition database 9 , a machining-related information generation base data storage section 11 , a machining-related information storage section 12 , a motion data storage section 15 and an NC machining program storage section 17 , and an input/output interface 18 , which are interconnected via bus lines, and an input device 19 and an output device 20 connected to the input/output interface 18 . Operating sections 21 of an NC machine tool as external devices are connected to the input/output interface 18 . The respective components of the numerical controller 1 will hereinafter be described in detail.

[0030] The CAD data storage section 2 stores therein CAD data of a product inputted from the input device 19 on an on-line basis or from a recording medium such as a floppy disk. The CAD data is prepared by means of a device separate from the numerical controller 1 of this embodiment, and includes design data indicative of the final configuration and dimensions of the product obtained after machining, for example, coordinates data and mathematical expression data for the product configuration, and data of a surface finish accuracy, a stock blank material and a stock blank configuration. The CAD data generally includes data unnecessary for generation of tool path data, e.g., data of dimension lines.

[0031] The configuration data generating section 3 extracts only data (e.g., configuration data) necessary for the generation of the tool path data from the CAD data stored in the CAD data storage section 2 by excluding data (e.g., dimension line data) unnecessary for the generation of the tool path data. The configuration data extracted by the configuration data generating section 3 is stored in the configuration data storage section 4 . FIG. 4 shows an exemplary product configuration to be displayed in a visual form on the basis of the configuration data stored in the configuration data storage section 4 . As shown, the product (workpiece) 30 has an undulated surface 31 (free-form surface), a projection (pyramid) 32 provided on the undulated surface 31 , and a recess 33 .

[0032] The process/machining model data generating section 5 performs a process shown in FIG. 2 . More specifically, the process/machining model data generating section 5 reads the configuration data out of the configuration data storage section 4 (Step S 1 ), and picks out machining areas to be subjected to machining from areas specified by the configuration data (Step S 2 ).

[0033] Then, three-dimensional configurational characteristics of the product in the machining areas are extracted for generation of characteristic data (Step S 3 ). This characteristic extracting operation includes two operations: a simple configuration extracting operation which is a relatively simple operation for extracting relatively simple configurational elements such as a cylindrical shape and a prismatic shape in the machining areas directly extracted from the configuration data; and free-form surface characteristic configuration extracting operation which is a relatively complex operation for extracting characteristic configurations such as free-form surfaces in the machining areas which cannot directly be extracted from the configuration data.

[0034] More specifically, the free-form surface characteristic configuration extracting operation is performed by an area projection method in this embodiment. In the extracting operation employing the area projection method, a virtual image constituted by a multiplicity of minute triangles are projected onto a workpiece surface obtained on the basis of the configuration data as shown in FIG. 5 . Then, normal lines are defined on the workpiece surface as extending from the respective minute triangular images formed on the workpiece surface, and the directions of the normal lines are analyzed for the extraction of the configurational characteristics in the machining areas. FIG. 5 illustrates the virtual image projected on the workpiece 30 of FIG. 4 .

[0035] In the case of a truncated-conical portion 34 as shown in FIG. 6 , normal lines 35 radially extend therefrom with no intersection. In the case of a vertical surface portion 36 as shown in FIG. 7 , normal lines 37 extend therefrom parallel to each other. In the case of an inclined surface portion 38 as shown in FIG. 8 , normal lines 39 extend therefrom at a certain angle with respect to the direction of the image projection. In the case of a concave portion, normal lines intersect with each other though not shown. Thus, the characteristic configurations in the machining areas can be determined by analyzing the directions of the normal lines. In the free-form surface characteristic configuration extracting operation, the characteristic configurations can be extracted in this manner.

[0036] On the basis of the characteristic data thus generated, process data is generated which is indicative of machining processes and machining areas for the respective machining processes (Step S 4 ). In this operation, the machining areas are defined as corresponding to the respective characteristic configurations, and then machining processes (e.g., rough machining, semi-finish machining and finish machining) are assigned to the respective machining areas. Alternatively, areas which can be subjected to machining with the use of the same tool are regarded as a single machining area, and a machining process (e.g., rough machining, semi-finish machining or finish machining) is assigned to the machining area.

[0037] Then, stock blank data indicative of a stock blank configuration and machining model data indicative of machining model configurations to be obtained after completion of the respective machining processes are generated on the basis of the product configuration data (Step S 5 ). The characteristic data, the process data, the stock blank data and the machining model data thus generated are stored in the process/machining model data storage section 6 (Step S 6 ). Thus, the process/machining model data generating section 5 completes the process.

[0038] The tool database 8 stores therein tool information including data indicative of the types (models, materials and the like) of tools and tool holders, dimensional data indicative of the diameters and lengths of the tools, and image data of the tools and the holders. The machining condition database 9 stores therein machining condition data indicative of machining modes (e.g., machining methods such as contour line machining, scanning line machining, linear interpolation, circular interpolation and method for air-cut avoidance) according to characteristic configurations, cutting speeds preset for the respective tool types according to stock blank materials, cutting amounts for each turn of the tools and cutting allowances. The machining condition data is inputted from the input device 19 .

[0039] The machining-related information generating section 10 generates tool path data and machining-related information on the basis of the characteristic data, the process data, the stock blank data and the machining model data stored in the process/machining model data storage section 6 , the tool data stored in the tool database 8 , and the machining condition data stored in the machining condition database 9 .

[0040] More specifically, the machining-related information generating section 10 performs a process as shown in FIG. 3 . A counter n is initialized (n=1) in Step S 11 . Then, characteristic data, process data, pre-machining model data (the stock blank data for the first machining process) and post-machining model data for an n-th machining process are read out of the process/machining model data storage section 6 in Step S 12 .

[0041] The machining model data thus read is analyzed to extract R-dimensions (radii) of round corner portions defined between adjacent pairs of faces of the product, and the minimum one of the R-dimensions is selected (Step S 13 ). A tool diameter (which is not greater than the minimum R-dimension) usable in the machining process is determined on the basis of the minimum R-dimension, and then the tool database 8 is searched to determine a tool (including a tool holder) to be used in the machining process on the basis of the tool diameter thus determined and other dimensional data (e.g., the depth of a hole in the case of drilling) obtained from the machining model data. To-be-used tool data indicative of the to-be-used tool thus determined is stored for each of the machining processes in the machining-related information generation base data storage section 11 (Step S 14 ).

[0042] Then, machining condition database 9 is searched to determine machining conditions for the machining process on the basis of the to-be-used tool data, the characteristic data, the process data and the stock blank data. Machining condition data indicative of the machining conditions thus determined is stored for each of the machining processes in the machining-related information generation base data storage section 11 (Step S 15 ). On the basis of the characteristic data, an optimum machining mode, cutting conditions and the like for each of the machining areas are determined and, where a machining cycle is repeatedly performed in the machining process, a feed pitch is determined on the basis of a finish surface roughness and the like. Where the same tool is used for machining in a plurality of machining areas, a sequence of machining operations to be performed in the respective machining areas is determined so that the machining operations can sequentially be performed in the machining areas in consideration of a machining efficiency.

[0043] The tool path data which includes data indicative of tool traveling paths, tool rotation speeds and tool traveling speeds is generated for the respective machining areas in accordance with the machining sequence on the basis of the to-be-used tool data, the characteristic data, the process data, the stock blank data and the machining model data. The tool path data thus generated is stored for each of the machining processes in the machining-related information generation base data storage section 11 (Step S 16 ).

[0044] A machining simulation is performed on the basis of the tool path data thus generated to optimize the machining conditions, and workpiece configuration data indicative of a workpiece configuration (virtual workpiece configuration) obtained after completion of the machining process in the simulation is stored for each of the machining processes in the machining-related information generation base data storage section 11 (Step S 17 ). The stock blank data indicative of the stock blank configuration is also stored in the machining-related information generation base data storage section 11 .

[0045] On the basis of the data generated in the aforesaid manner and stored in the machining-related information generation base data storage section 11 , the amount of the wear of the tool, the time expected to lapse until the tool reaches a wear limit, the time expected to be required for a preparatory operation for the machining, the time expected to be required for the machining, and a machining cost estimated for the machining process are calculated, and machining operation information data indicative of machining operation information including the estimation, the workpiece configurations (image-based information) before and after the machining process and set-up information (model and image-based information) is generated. The machining operation information data thus generated and the tool path data are stored as machining-related information in the machining-related information storage section 12 (Step S 18 ).

[0046] The machining-related information generating section 10 performs the aforesaid process for the respective machining processes to generate the aforesaid data for the respective machining processes, and the machining-related information is stored for the respective machining processes in the machining-related information storage section 12 (Steps S 19 , S 20 ). Thus, the machining-related information generating section 10 completes the process.

[0047] Exemplary machining-related information to be generated by the machining-related information generating section 10 is shown in FIGS. 9 to 17 . FIGS. 9 to 11 each show tool set-up information (tool preparation information) for a machining process (e.g., a rough machining process, a semi-finish machining process or a finish machining process) in a table form, which includes workpiece images before and after the machining process, the types, makers, dimensions, images of a tool and a tool holder, a tool number and a offset number. FIGS. 12 to 16 each show machining condition information for a machining process in a table form, which includes a workpiece image after the machining process, a tool number, tool dimensions, cutting conditions, a machining method, a machining time and a tool wear amount. FIG. 17 shows in a table form the outline of the machining to be performed on the workpiece in the respective machining processes, which includes the workpiece images before and after the respective machining processes and machining operations to be performed in the respective machining processes. In view of such information, an operator can promptly and correctly understand the tools required for the respective machining processes, machining operations to be performed in the respective machining processes and the outline of the whole machining process.

[0048] The motion data generating section 14 generates motion data required for directly driving the servo mechanism and the like provided in the NC machine tool. More specifically, the motion data is generated on the basis of the tool path data stored in the machining-related information storage section 12 . Then, the motion data thus generated is outputted to the operating sections 21 of the NC machine tool via the input/output interface 18 , and stored in the motion data storage section 15 . The operating sections 21 of the NC machine tool are driven on the basis of the motion data, whereby the workpiece is machined.

[0049] The machining-related information rewriting section 13 changes the data stored in the machining-related information storage section 12 . This is achieved by receiving data inputted from the input device 19 . When the machining-related information is changed, the data stored in the tool database 8 and the machining condition database 9 is updated with the changed data by the tool/machining condition database updating section 7 . With the data updating function, knowledge obtained by the actual machining can be reflected on the next machining. That is, a so-called learning function can be provided. The tool/machining condition database updating section 7 is also adapted to receive data inputted from the input device 19 , and update the data stored in the tool database 8 and the machining condition database 9 with the inputted data.

[0050] In this embodiment, the NC machining program generating section 16 is provided for generating an NC machining program on the basis of the tool path data generated in the aforesaid manner. The NC machining program generating section 16 generates a commonly used NC machining program (e.g., in an ISO format) on the basis of the tool path data stored in the machining-related information storage section 12 , and stores the generated NC machining program in the NC machining program storage section 17 .

[0051] The output device 20 includes a display device, a printing device and a device for storing data in a recording medium such as a floppy disk. The data stored in the CAD data storage section 2 , the configuration data storage section 4 , the process/machining model data storage section 6 , the tool database 8 , the machining condition database 9 , the machining-related information generation base data storage section 11 , the machining-related information storage section 12 , the motion data storage section 15 and the NC machining program storage section 17 can be displayed on the display device, printed out by the printing device, and stored in the recording medium (e.g., floppy disk). After the data stored in the machining-related information storage section 12 is displayed on the display device or printed out by the printing device, the operator can analyze the data for the correction of the data. Since the NC machining program can be stored in the recording medium, the NC machining program can be transported to a second NC machine tool via the recording medium for execution thereof on the second NC machine tool.

[0052] As detailed above, the numerical controller 1 according to this embodiment obviates the need for the operator to input the data of the characteristic configurations of the workpiece and the data of the machining methods indicative of the to-be-used tools and the cutting conditions, so that the data input time is obviated. Therefore, the tool path data can speedily be generated, thereby effectively speeding up the workpiece machining. In addition, human errors in the data input can be eliminated, thereby preventing production of defective workpieces and damages to jigs and tools which may otherwise occur due to the input errors. The numerical controller is particularly advantageous in the case of machining for production of a uniquely customized product such as a mold.

[0053] Further, the machining-related information including information required for the preparatory operation for the machining can automatically be generated, so that human errors in a worksheet formulating operation can be prevented to streamline the worksheet formulating operation. By utilizing the machining-related information thus generated, the preparatory operation for the machining can easily be performed in a shorter time. Further, the machining time can preliminarily be estimated, so that an optimum time slot (daytime or nighttime) can be selected for the machining. If a machining operation is expected to be completed in a short time, the machining operation may be performed during an operator-attended operation period and, after the completion of the machining operation, the operator may perform the next workpiece machining operation or the next preparatory operation. Thus, the productivity can be improved. On the other hand, if a machining operation is expected to require much time, the machining operation may be performed during a nighttime non-attended operation period. Further, the number of tools required for the machining and the machining time can be estimated, making it possible to preliminarily calculate the costs for the machining of the workpiece. Therefore, cost estimation can promptly be provided.

[0054] While the present invention has thus been described by way of the embodiment thereof, it should be understood that the invention is not limited to the embodiment. Although the machining-related information generating apparatus including the processing sections such as the configuration data generating section 3 , the process/machining model data generating section 5 , the tool/machining condition database updating section 7 , the machining-related information generating section 10 , the machining-related information rewriting section 13 , the motion data generating section 14 and the NC machining program generating section 16 , and storage sections such as the CAD data storage section 2 , the configuration data storage section 4 , the process/machining model data storage section 6 , the tool database 8 , the machining condition database 9 , the machining-related information generation base data storage section 11 , the machining-related information storage section 12 , the motion data storage section 15 and the NC machining program storage section 17 is incorporated in the numerical controller 1 of the NC machine tool in the embodiment described above, the machining-related information generating apparatus may be provided as a stand-alone apparatus separate from the numerical controller 1 . In this case, the input/output interface 18 , and the input device 19 and the output device 20 connected to the input/output interface 18 are preferably provided in the machining-related information generating apparatus.