Automatic programming method and device for creating multi-path program

The present application is based on, and claims priority from, Japanese Application Number 2010-095507, filed Apr. 16, 2010, the disclosure of which is hereby incorporated by reference herein in its entirety.

1. Field of the Invention

The present invention relates to an automatic programming method and device for creating multi-path programs.

2. Description of the Related Art

To create a multi-path machining program that provides the shortest machining time, the operator should perform complicated calculation to determine the following three items:

(1) paths that perform machining processes in the shortest machining time;

(2) machining process orders that provide the shortest machining time; and

(3) machining processes to be simultaneously performed.

Japanese Patent Application Laid-Open No. 10-086040 discloses a technique for creating programs for a multi-path machine tool by automatically creating information of (1) a path workable for each of the machining processes, (2) a machining process order in each path, and (3) an inter-path waiting order, on the basis of information of workable tools in each path, workpiece information for each machining process, and a path priority decision rule. This technique, however, cannot create a program that provides the shortest machining time.

On the other hand, Japanese Patent Application Laid-Open No. 07-068448 discloses a technique for enabling simultaneous machining by determining the machining order that provides the shortest machining time and automatically adjusting the cutting-in amount in the machining processes that cannot be simultaneously performed. In this technique, however, the order of machining processes and the paths performing the machining processes are predetermined and cannot be automatically determined. Furthermore, this technique only determines a combination of simultaneously performed machining processes that provides the shortest machining time and cannot change the order of machining processes or change the working paths. This technique also has a problem that a machining program that provides the shortest machining time should be searched for through a trial-and-error process of changing the order and calculating the machining time each time.

In view of the problems with the conventional techniques described above, an object of the present invention is to provide an automatic programming device that can create multi-path machining programs that provide the shortest machining time by creating all machining programs that meet three condition to be input by the operator which include (1) workable paths for each machining process, (2) workable orders of machining processes, and (3) simultaneously workable machining processes, and selecting machining programs that provide the shortest machining time on the basis of the machining time of each machining process.

To achieve the above object, an automatic programming device according to the present invention creates multi-path programs for a machine having a plurality of control paths performing one or more machining processes of a machining program for machining a workpiece. This automatic programming device includes machining process creating means for creating machining processes for machining a workpiece, calculating means for calculating the machining time of each machining process, path input means for inputting paths workable for each of the machining processes created by the machining process creating means, machining order input means for inputting workable orders of the machining processes, simultaneously workable machining process input means for inputting, for each of the machining processes, simultaneously workable machining processes if any among the other machining processes, and selecting means for selecting machining programs that provide the shortest machining time on the basis of the machining processes created by the machining process creating means, the machining time calculated by the calculating means, the workable paths input by the path input means, the workable machining orders input by the machining order input means, and the simultaneously workable machining processes input by the simultaneously workable machining process input means.

An automatic programming method according to the present invention creates multi-path programs for a machine having a plurality of control paths performing one or more machining processes of a machining program for machining a workpiece. This method includes the steps of:

(1) creating machining processes for machining a workpiece;

(2) calculating the machining time of each of the machining processes;

(3) inputting paths workable for each of the machining processes created by the machining process creating means;

(4) inputting workable orders of the machining processes;

(5) inputting, for each of the machining processes, simultaneously workable machining processes if any among the other machining processes; and

(6) selecting machining programs that provide the shortest machining time on the basis of the machining processes created in the step (1), the machining time calculated in the step (2), the workable paths input in the step (3), the workable machining orders input in the step (4), and the simultaneously workable machining processes input in the step (5).

The present invention can thus provide an automatic programming device and method that can create multi-path machining programs that provide the shortest machining time by creating all machining programs that meet the three condition to be input by the operator, i.e., paths workable for each machining process, workable orders of the machining processes, and simultaneously workable machining processes, and selecting machining programs that provide the shortest machining time on the basis of the machining time of each machining process.

The above and other objects and features of the present invention will become apparent from the following description of embodiments with reference to the accompanying drawings, in which:

FIG. 1A illustrates a two-path lathe (one spindle);

FIG. 1B illustrates a two-path lathe (one spindle) with a milling head;

FIG. 1C illustrates a two-path lathe (two spindles);

FIG. 2A illustrates a two-path lathe (two spindles);

FIG. 2B illustrates a two-path lathe (two spindles) with a milling head;

FIG. 3A illustrates a three-path lathe (two spindles);

FIG. 3B illustrates a three-path lathe (two spindles) with a milling head;

FIG. 4 illustrates a four-path lathe (two spindles);

FIG. 5 is a schematic view of a numerical controller serving as the automatic programming device for a multi-path machine according to the present invention;

FIG. 6 illustrates regions to be machined in machining processes ( 1 )-( 4 );

FIG. 7 illustrates condition to be input by an operator;

FIG. 8 is a flowchart illustrating an algorithm for the entire processing of automatic programming for creating a multi-path program;

FIG. 9 is a flowchart illustrating an algorithm for the processing of determining all the combinations of working sequences that meet the conditions for workable orders;

FIG. 10 illustrates inputs to the processing for executing the flowchart shown in FIG. 9 , sequence buffers created in storage areas, and storage areas for storing determined working sequences;

FIG. 11 is a flowchart illustrating an algorithm for the processing of computing combinations of paths working on the machining processes;

FIG. 12 illustrates inputs to the processing for executing the flowchart shown in FIG. 11 , working path buffers created in storage areas, and storage areas for storing determined working paths;

FIG. 13 is a flowchart illustrating an algorithm for the processing of computing all the combinations of machining processes that are simultaneously workable, if possible, with the previous and/or following machining process thereof;

FIG. 14 illustrates inputs to the processing for executing the flowchart shown in FIG. 13 , a simultaneous machining buffer created in a storage area, and a storage area for storing determined simultaneously workable machining processes;

FIG. 15 illustrates how all the combinations of working sequences that meet the conditions for workable orders are determined;

FIG. 16 illustrates how all the combinations of paths working on the machining processes are computed;

FIG. 17 illustrates how all the combinations of machining processes that are simultaneously performed, if possible, with the previous and/or following process thereof are computed;

FIG. 18 illustrates how the machining time of each machining process is determined; and

FIG. 19 illustrates how the machining programs that provide the shortest machining time are selected.

FIGS. 1A-4 illustrate multi-path lathes. FIG. 1A illustrates a two-path lathe (one spindle), FIG. 1B illustrates a two-path lathe (one spindle) with a milling head, and FIG. 1C illustrates a two-path lathe (two spindles). FIG. 2A illustrates a two-path lathe (two spindles), and FIG. 2B illustrates a two-path lathe (two spindles) with a milling head. FIG. 3A illustrates a three-path lathe (two spindles), and FIG. 3B illustrates a three-path lathe (two spindles) with a milling head. FIG. 4 illustrates a four-path lathe (two spindles).

FIG. 5 is a schematic view of main units of a numerical controller serving as the automatic programming device for a multi-path machine according to the present invention. The numerical controller 50 can machine a workpiece by driving and controlling any of the multi-path lathes shown in FIGS. 1A-4 according to a machining program.

The numerical controller 50 includes a processor 51 , a memory 52 such as ROM, RAM, non-volatile RAM, or the like, a display device 53 including a liquid crystal display device or the like, an input means 54 including a keyboard for inputting data and commands, and 1st to n-th path spindle control circuits 55 - 1 to 55 - n for controlling the motors for driving the movable shafts of a plurality of paths. The memory 52 , display device 53 , input means 54 , and control circuits 55 - 1 to 55 - n are connected to the processor 51 via a bus 56 .

The memory 52 stores, in addition to programs for each path, software for editing the programs and, in particular, software for the automatic programming for a multi-path machine according to the present invention.

The 1st to n-th path spindle control circuits 55 - 1 to 55 - n perform position/speed feedback control according to the moving commands distributed by the processor 51 executing the programs of individual paths and on the basis of feedback signals from position/speed sensors associated with the motors, and control the motors of individual paths by current feedback to move the spindles of individual paths separately or synchronously in a coordinated manner. This multi-path driving and control operation by the numerical controller 50 is the same as the driving and control operation by conventional numerical controllers having a multi-path control function. The automatic programming device according to the present invention may include an information processing device such as a personal computer.

FIG. 6 illustrates regions of a workpiece to be machined by machining processes ( 1 )- 4 ). Reference numerals ( 1 )-( 4 ) in FIG. 6 indicate a machining order of the workpiece. FIG. 6 shows an example of machining of a workpiece W using one of the two-path lathes shown in FIGS. 1A-1C and FIGS. 2A-2B in the machining processes ( 1 )-( 4 ).

As can be seen from FIG. 6 , an operator should perform the machining process ( 2 ) after the machining process ( 1 ), perform the machining process ( 3 ) after the machining process ( 1 ), and perform the machining process ( 4 ) after the machining process ( 3 ). The operator can recognize that the machining process ( 2 ) can be performed simultaneously with the machining process ( 3 ) or ( 4 ), the machining process ( 3 ) can be performed simultaneously with the machining process ( 2 ), and the machining process ( 4 ) can be performed simultaneously with the machining process ( 2 ). The operator can also recognize which path should be used for each machining process depending on the machining types of individual machining processes.

FIG. 7 shows an example of input screen. As described with reference to FIG. 6 , the operator can input conditions for workable orders of machining processes, paths workable for each of the machining processes, and data of simultaneously workable machining processes to the automatic programming device for creating multi-path programs (see FIG. 5 ). The automatic programming device for creating multi-path programs stores the information input by the operator in a storage device (memory 52 in FIG. 5 ).

NOs. ( 1 ), ( 2 ), ( 3 ), and ( 4 ) indicate the machining process numbers and “machining type” indicates the type of machining to be performed in each machining process.

For the conditions for performing machining processes, the workable orders are set for each machining process. The workable paths are set for each machining process. The data of simultaneously workable machining processes is stored.

In the exemplary input screen shown in FIG. 7 , there are four “machining processes” and two “workable paths”, i.e., paths 1 and 2 . The number of “machining processes” is not limited, however, to four and the number of “workable paths” is not limited to paths 1 and 2 .

As described above, FIG. 7 is an example of condition to be input to the automatic programming device for machining the workpiece W with a machine including paths 1 and 2 according to a machining program including four machining processes. If the number of machining processes increases or the number of paths in a machine increases, a corresponding input screen is displayed.

FIG. 8 is a flowchart illustrating an algorithm for the entire processing of automatic programming for creating multi-path programs. This algorithm will now be described in the order of steps.

[Step SA 100 ] Determine the machining time of each of all machining processes. The method of determining the machining time of each machining process on the basis of the moving speed of the movable shaft, machining distance, and other data is conventionally known, so detailed description thereof is omitted.

[Step SA 101 ] Initialize ‘h’ indicating the nest counter and sequence number to 1 (h=1).

[Step SA 102 ] Determine all the combinations of working sequences that meet the conditions for workable orders. More specifically, all the combinations of working sequences can be determined by the processing shown in the flowchart in FIG. 9 .

[Step SA 103 ] Set K=1. K indicates a sequence number that meets the conditions for workable orders.

[Step SA 104 ] Initialize ‘j’ indicating the nest counter and sequence number to 1 (j=1).

[Step SA 105 ] Compute all the combinations of working paths in the K-th working sequence. More specifically, all the combinations of working paths are computed by the processing shown in the flowchart in FIG. 11 .

[Step SA 106 ] Set L=1. L is the number of a working path combination in the K-th working sequence.

[Step SA 107 ] Initialize ‘s’ indicating the nest counter and sequence number to 1 (s=1).

[Step SA 108 ] Compute all the combinations of simultaneously workable machining processes in the L-th combination of working paths. More specifically, all the combinations of simultaneously workable machining processes are computed by the processing shown in the flowchart in FIG. 13 .

[Step SA 109 ] Set M=1. M is the number of a simultaneously workable machining process combination in the L-th working path combination.

[Step SA 110 ] Calculate the machining time of the entire program in the M-th simultaneously workable machining process combination.

[Step SA 111 ] Check whether or not the machining time is shortest; if shortest, proceed to step SA 112 , if not, proceed to step SA 113 .

[Step SA 112 ] Store the shortest machining time and the program that provides the shortest machining time.

[Step SA 113 ] Add 1 to M to update M.

[Step SA 114 ] Check whether or not M is greater than Mmax; if greater, proceed to step SA 115 ; if not, proceed to step SA 110 .

[Step SA 115 ] Add 1 to L to update L.

[Step SA 116 ] Check whether or not L is greater than Lmax; if greater, proceed to step SA 117 ; if not, proceed to step SA 107 .

[Step SA 117 ] Add 1 to K to update K.

[Step SA 118 ] Check whether or not K is greater than Kmax; if greater, end the processing; if not, proceed to step SA 104 to continue the processing.

In the above flowchart, Kmax is the number of working sequences that meet the conditions for workable orders; Lmax is the number of working path combinations in a working sequence; and Mmax is the number of combinations of simultaneously workable machining processes.

FIG. 9 is a flowchart illustrating an algorithm for the processing of determining all the combinations of working sequences that meet the conditions for workable orders. This algorithm will now be described in the order of steps. Here, n is the total number of machining processes and h is the nest counter and sequence number.

[Step SB 100 ] Initialize i indicating the machining process number to 1 (i=1).

[Step SB 101 ] Copy data from the sequence buffer for nest h−1 to the sequence buffer for nest h. When h=1, there is no data to be copied, so the processing in this step is not performed.

[Step SB 102 ] Check whether or not machining process (i) is present in the sequence buffer for nest h; if present, proceed to step SB 110 ; if not, proceed to step SB 103 .

[Step SB 103 ] Check whether or not machining process (i) is in a workable order; if in a workable order, proceed to step SB 104 ; if not, proceed to step SB 110 .

[Step SB 104 ] Store machining process (i) in the h-th location in the sequence buffer for nest h.

[Step SB 105 ] Check whether or not n machining processes have been stored in the sequence buffer for nest h; if stored, proceed to step SB 106 ; if not, proceed to step SB 107 .

[Step SB 106 ] Store the determined working sequence.

[Step SB 107 ] Add 1 to h to update h.

[Step SB 108 ] Make a recursive call.

[Step SB 10 ] Subtract 1 from h to update h.

[Step SB 110 ] Add 1 to i to update i.

[Step SB 111 ] Check whether or not i is greater than n; if greater, end the processing; if not, return to step SB 102 to continue the processing,

FIG. 10 illustrates inputs to the processing for executing the flowchart shown in FIG. 9 , sequence buffers generated in storage areas, and storage areas for storing determined working sequences. “Inputs to processing” in FIG. 10( a ) are data passed from the processing shown in the flowchart in FIG. 8 to the processing shown in the flowchart in FIG. 9 . As shown in FIG. 10( a ), the data input to the processing shown in the flowchart in FIG. 9 are n indicating the total number of machining processes, workable orders of machining processes, and h indicating the nest counter and sequence number. Shown in FIG. 10( b ) are buffers generated during recursive processing in step SB 108 in FIG. 9 . Shown in FIG. 10( c ) are storage areas in which the determined working sequences are stored in step SB 106 in FIG. 9 .

FIG. 11 is a flowchart illustrating an algorithm for the processing of computing combinations of working paths for the machining processes. This algorithm will now be described in the order of steps. Here, n is the total number of machining processes and j is the sequence number.

[Step SC 100 ] Copy data from the machining path buffer for nest j−1 to the machining path buffer for nest j. When j=1, there is no data to be copied, so the processing in this step is not executed.

[Step SC 101 ] Check whether or not the path 1 is workable for the j-th machining process in the machining path buffer for nest j; if workable, proceed to step SC 102 ; if not, proceed to step SC 109 .

[Step SC 102 ] Set 1 to the working path for the j-th machining process in the machining path buffer for nest j.

[Step SC 103 ] Check whether or not working paths have been determined for n machining processes in the machining path buffer for nest j; if determined, proceed to step SC 104 ; if not, proceed to step SC 105 .

[Step SC 104 ] Store the determined working paths and proceed to step SC 108 .

[Step SC 105 ] Add 1 to j to update j.

[Step SC 106 ] Make a recursive call.

[Step SC 107 ] Subtract 1 from j to update j.

[Step SC 108 ] Check whether or not the path 2 is workable for the j-th machining process in the machining path buffer for nest j; if workable, proceed to step SC 109 ; if not, proceed to step SC 110 .

[Step SC 109 ] Set 2 to the working path for the j-th machining process in the machining path buffer for nest j.

[Step SC 110 ] Check whether or not working paths have been determined for n machining processes in the machining path buffer for nest j; if determined, proceed to step SC 111 ; if not, proceed to step SC 112 .

[Step SC 111 ] Store the determined working paths.

[Step SC 112 ] Add 1 to j to update j.

[Step SC 113 ] Make a recursive call.

[Step SC 114 ] Subtract 1 from j to update j and end the processing.

Shown in FIG. 12 are inputs to the processing for executing the flowchart shown in FIG. 11 , working path buffers generated in storage areas, and storage areas for storing the determined working paths. “Inputs to processing” in FIG. 12( a ) are data passed from the processing shown in the flowcharts in FIGS. 8 and 9 to the processing shown in the flowchart in FIG. 11 . Shown in FIG. 12( b ) are buffers generated during the recursive processing in steps SC 106 and SC 113 in FIG. 11 . Shown in FIG. 12( c ) are storage areas in which the determined working paths are stored in steps SC 104 and SC 111 in FIG. 11 .

FIG. 13 is a flowchart illustrating an algorithm for the processing of computing all the combinations of machining processes that are simultaneously performed if possible with the previous and/or following step thereof. This algorithm will now be described in the order of steps. Here, n is the total number of machining processes and s is the sequence number.

[Step SD 100 ] Copy data from the simultaneous machining buffer for nest s−1 to the simultaneous machining buffer for nest s.

[Step SD 101 ] Check whether or not the s-th simultaneous machining process number in the simultaneous machining buffer for nest s has already been set; if already set, proceed to step SD 111 ; if not, proceed to step SD 102 .

[Step SD 102 ] Check whether or not the s-th and s−1-th machining processes in the simultaneous machining buffer for nest s are simultaneously workable; if simultaneously workable, proceed to step SD 103 ; if not, proceed to step SD 104 .

[Step SD 103 ] Set s−1 for the s-th simultaneous machining process number in the simultaneous machining buffer for nest s.

[Step SD 104 ] Check whether or not simultaneous working of machining processes has been determined for n machining processes in the simultaneous machining buffer for nest s; if determined, proceed to step SD 105 ; if not, proceed to step SD 106 .

[Step SD 105 ] Store the determined combinations of simultaneously working machining processes.

[Step SD 106 ] Add 1 to s to update s.

[Step SD 107 ] Make a recursive call.

[Step SD 108 ] Subtract 1 from s to update s.

[Step SD 109 ] Check whether or not the s-th and s+1-th machining processes in the simultaneous machining buffer for nest s are simultaneously workable; if simultaneously workable, proceed to step SD 110 ; if not, proceed to step SD 111 .

[Step SD 110 ] Set s+1 for the s-th simultaneous machining process number in the simultaneous machining buffer for nest s.

[Step SD 111 ] Check whether or not simultaneous working of machining processes has been determined for n machining processes in the simultaneous machining buffer for nest s; if determined, proceed to step SD 112 ; if not, proceed to step SD 113 .

[Step SD 112 ] Store the determined combinations of simultaneously working machining processes.

[Step SD 113 ] Add 1 to s to update s.

[Step SD 114 ] Make a recursive call.

[Step SD 115 ] Subtract 1 from s to update s and end the processing.

FIG. 14 illustrates inputs to the processing for executing the flowchart shown in FIG. 13 , a simultaneous machining buffer generated in a storage area, and a storage area for storing the determined simultaneously working machining processes. “Inputs to processing” in FIG. 14( a ) are data passed from the processes shown in the flowcharts in FIGS. 8 , 9 , and 11 to the processing shown in the flowchart in FIG. 13 . Shown in FIG. 14( b ) is a buffer generated during the recursive processing in steps SD 107 and SD 114 in FIG. 13 . Shown in FIG. 14( c ) is a storage area in which the determined simultaneously working machining processes are stored in steps SD 105 and SD 112 in FIG. 13 .

Next, the processing in FIGS. 8 , 9 , 11 , and 13 will be described with reference to the examples shown in FIGS. 6 , 7 , and 15 - 19 .

As described above, FIG. 6 shows how the workpiece W is machined in the machining processes ( 1 )-( 4 ). FIG. 7 illustrates the condition to be input to the automatic programming device (for example, to the numerical controller 50 ) for a multi-path machine for performing machining operations shown in FIG. 6 . FIG. 7 illustrates the condition to be input by the operator. The operator inputs conditions for workable orders of machining processes, workable paths for each of the machining processes, and conditions for simultaneously workable machining processes.

FIG. 15 illustrates how all the combinations of working sequences that meet the conditions for workable orders are determined. Three working sequences indicated by reference numerals 1 , 3 , and 4 in FIG. 15 are determined to meet the conditions for workable orders of machining processes shown in FIG. 7 by the processing of algorithm shown in FIG. 9 .

Next, the working sequences that meet the conditions for workable orders of machining processes are computed by the processing of algorithm shown in FIG. 11 and six path combinations shown in FIGS. 16 (A)-(F) are determined to meet the conditions shown in FIG. 7 . FIG. 16 illustrates how all the combinations of working paths for the machining processes are computed.

Reference numerals ( 1 - 1 ) and ( 1 - 2 ) in FIG. 16 indicate all the combinations of paths working on the machining processes in the sequence indicated by reference numeral 1 in FIG. 15 . Reference numerals ( 3 - 1 ) and ( 3 - 2 ) indicate all the combinations of paths working on the machining processes in the sequence indicated by reference numeral 3 in FIG. 15 . Reference numerals ( 4 - 1 ) and ( 4 - 2 ) indicate all the combinations of paths working on the machining processes in the sequence indicated by reference numeral 4 in FIG. 15 .

Through the processing of algorithm shown in FIG. 13 on all the combinations of paths working on the machining processes shown in FIG. 16 , the combinations indicated by reference numerals ( 1 - 1 - 1 ), ( 3 - 2 - 1 ), and ( 3 - 2 - 2 ) in FIG. 17 are determined to meet the conditions shown in FIG. 7 .

Next, the processing of algorithm shown in FIG. 8 calculates the machining time of each of the machining processes indicated by reference numerals ( 1 - 1 - 1 ), ( 3 - 2 - 1 ), and ( 1 - 1 - 2 ) in FIG. 17 . The calculation results are indicated by reference numerals ( 1 - 1 - 1 - 1 ), ( 3 - 2 - 1 - 1 ), and ( 1 - 1 - 2 - 2 ) in FIG. 18 . The shortest machining time is provided by two machining programs of the sequences indicated by reference numerals ( 3 - 2 - 1 - 1 ) and ( 1 - 1 - 2 - 2 ) shown in FIG. 19 .