MACHINING SYSTEM, SEARCH METHOD, AND SEARCH PROGRAM

A machining system that uses a plurality of tools to machine a workpiece includes a display unit capable of displaying a search screen for searching for a tool. The search screen can accept input of a search condition related to the remaining lifespan of a tool. The machining system also includes a search unit for searching for a tool whose remaining lifespan or amount of usage satisfies the search condition, among the plurality of tools, based on the amount of usage of each of the tools from a new state. The search screen displays information regarding a tool that satisfies the search condition as a search result.

TECHNICAL FIELD

The present disclosure relates to a technology for searching tool information.

BACKGROUND ART

The larger the number of machine tools to manage is, the more difficult it is to manage tools used in each machine tool. In this respect, Patent Document 1 (International Publication No. 2015/029232) discloses a tool management system. A tool database is stored in this tool management system. Tool data specifies the length, diameter, or the like of each tool.

CITATION LIST

Patent Document

SUMMARY OF INVENTION

Technical Problem

Each tool has a limited lifespan. It is recommended to replace a tool that has reached the end of the lifespan thereof with a new tool. The larger the number of tools used is, the more difficult tool replacement work is. Therefore, tool replacement work is performed altogether during a hiatus or the like. Here, for the efficiency of tool replacement work, it is favorable to perform replacement work not only for tools that have reached the end of the lifespan, but also for tools that are about to reach the end of the lifespan thereof.

To assist in such tool replacement work, there is demand for a technology for searching tool information using search conditions regarding the remaining lifespan of the tools. Note that Patent Document 1 mentioned above does not disclose anything regarding this type of technology.

Solution to Problem

In an example of the present disclosure, a machining system in which a plurality of tools are used to machine a workpiece includes a display unit capable of displaying a search screen for searching for a tool. The search screen is capable of accepting input of a search condition related to a remaining lifespan of a tool. The machining system also includes a search unit for searching for a tool whose remaining lifespan or amount of usage satisfies the search condition, among the plurality of tools, based on an amount of usage of each of the tools from a new state. The search screen displays, as a search result, information regarding a tool that satisfies the search condition.

In an example of the present disclosure, the machining system includes: a machine tool; a tool storage section in which a plurality of tools are able to be stored; a workstation for a worker to perform work for a tool; and a transfer device for transferring a designated tool among a tool in the machine tool, a tool in the tool storage section, and a tool in the workstation, to a designated delivery destination, which is one of the machine tool, the tool storage section, and the workstation. Search targets on the search screen include a tool in the machine tool, a tool in the tool storage section, and a tool in the workstation.

In an example of the present disclosure, the search screen is capable of accepting a selection operation to select a piece of information regarding each tool displayed as the search result. The machining system further includes a transfer control unit for controlling the transfer device so as to transfer a tool corresponding to the piece of information selected by the selection operation to the workstation.

In an example of the present disclosure, information regarding each tool displayed as the search result on the search screen includes identification information regarding the tool, and a remaining lifespan of the tool or an amount of usage of the tool.

In an example of the present disclosure, the information regarding each tool displayed as the search result on the search screen further includes information regarding a property of the tool.

In an example of the present disclosure, the information regarding each tool displayed as the search result on the search screen further includes a classification of the tool.

In an example of the present disclosure, the search unit searches for a tool whose remaining lifespan satisfies the search condition among the plurality of tools. The search condition able to be input on the search screen includes at least one of a proportion of a remaining lifespan of a tool to a lifespan of the tool from a new state and a proportion of an amount of usage of the tool to the lifespan of the tool from the new state.

In another example of the present disclosure, a search method for searching for a specific tool among a plurality of tools to be used in a machining system is provided. The search method includes: a step of displaying a search screen for searching for a tool; a step of accepting input of a search condition related to a remaining lifespan of a tool on the search screen; a step of searching for a tool whose remaining lifespan or amount of usage satisfies the search condition, among the plurality of tools, based on an amount of usage of each of the tools from a new state; and a step of displaying information regarding a tool that satisfies the search condition as a search result on the search screen.

In another example of the present disclosure, a search program for searching for a specific tool among a plurality of tools to be used in a machining system is provided. The search program causes a computer to execute: a step of displaying a search screen for searching for a tool; a step of accepting input of a search condition related to a remaining lifespan of a tool on the search screen; a step of searching for a tool whose remaining lifespan or amount of usage satisfies the search condition, among the plurality of tools, based on an amount of usage of each of the tools from a new state; and a step of displaying information regarding a tool that satisfies the search condition as a search result on the search screen.

The above and other objects, features, aspects and advantages of the present invention will become apparent from the following detailed description of the invention as understood in connection with the accompanying drawings.

DESCRIPTION OF EMBODIMENTS

Hereinafter, embodiments according to the present invention will be described with reference to the drawings. In the following description, identical components and constituent elements are given identical reference signs. Those components and constituent elements also have the same names and functions. Accordingly, detailed descriptions thereof are not repeated. Note that the following embodiments and variations may be selectively combined as appropriate.

An overview of a tool search function is described with reference toFIG.1.FIG.1schematically shows a flow of tool information search processing.

A machining system1is shown inFIG.1. The machining system1is a system capable of machining a workpiece using a plurality of tools. The machining system1includes an information processing device5and a display106(display unit).

The information processing device5is a device for managing the tools used in the machining system1. The information processing device5may be constituted by a single computer or a plurality of computers. The computer may be a desktop PC (Personal Computer), a laptop PC, or a mobile terminal. As an example, the information processing device5is a later-described management device100(seeFIG.3) or a later-described operation terminal200A (seeFIG.3).

The display106is, for example, a liquid-crystal display, an organic EL (Electro Luminescence) display, or other display equipment. The display106may be integrated with or separate from the information processing device5.

A tool database123is stored in the information processing device5. Various types of information regarding the tools are specified in the tool database123. As an example, in the tool database123, the maximum usable time of a tool, the current amount of usage of the tool, and the remaining lifespan of the tool are associated with each other according to identification information regarding each tool.

The identification information regarding each tool specified in the tool database123is information for uniquely identifying the tool. The identification information is assigned to each tool in advance. As an example, the identification information may be indicated by a tool number such as an ID (Identification), or a tool name.

The maximum usable amount specified in the tool database123is an indicator of the amount of usage of the tool from the new state until the tool reaches the end of the lifespan thereof. The term “maximum usable amount of a tool” includes, for example, the time that the tool can be used for machining from the new state until the tool reaches the end of the lifespan thereof, the distance that the tool can move during machining from the new state until the tool reaches the end of the lifespan thereof, and the number of times that the tool can be used from the new state until the tool reaches the end of the lifespan thereof.

The current amount of usage specified in the tool database123is an indicator of the amount of usage of the tool from the new state to the present. The term “amount of usage of a tool” includes, for example, the total time that the tool has been used for machining since the new state to the present, the total distance that the tool has moved during machining since the new state to the present, and the total number of times that the tool has been used since the new state to the present.

The remaining lifespan specified in the tool database123is an indicator of the amount of usage of the tool from the present until the tool reaches the end of the lifespan thereof. The term “remaining lifespan of a tool” includes, for example, the time that the tool can be used for machining from the present until the tool reaches the end of the lifespan thereof, the distance that the tool can move during machining from the present until the tool reaches the end of the lifespan thereof, and the number of times that the tool can be used from the present until the tool reaches the end of the lifespan thereof.

The information processing device5has a function of searching tool information. The search function is realized by a search screen130for searching tool information, for example. The search screen130is displayed on the display106, for example.

The search screen130accepts input of various search conditions. A search condition may be input to an input area131of the search screen130. Input of the search condition to the input area131is realized by operating an input device, such as a mouse, or by touching the display106, for example.

The search screen130accepts input of a search condition related to the remaining lifespan of tools. In the example inFIG.1, the search screen130accepts the proportion of the remaining lifespan of a tool to the maximum usable amount of the tool (hereinafter also referred to as “remaining lifespan proportion”) as a search condition.

The information processing device5identifies tools whose remaining lifespan satisfies the search condition among the tools specified in the tool database123, based on the current amount of usage of each tool used in the machining system1. Thereafter, the search screen130displays information regarding the identified tools in a display field132for search results.

In the example inFIG.1, a remaining lifespan proportion of “10% or less” is input as a search condition. In this case, the information processing device5identifies tool information including a remaining lifespan proportion of “10% or less” from the tool database123. In the example inFIG.1, the remaining lifespan proportion of a tool A is 90% (=900/1000), the remaining lifespan proportion of a tool B is approximately 67% (=1000/1500), the remaining lifespan proportion of a tool C is 0% (=0/1200), and the remaining lifespan proportion of a tool D is 1.1% (=15/1300). Therefore, the search screen130displays information regarding the tool C and the tool D in the display field132.

Thus, the worker can search tool information with a search condition related to the remaining lifespan by means of the search function of the machining system1. This allows the worker to understand not only tools that have reached the end of the lifespan thereof but also tools that are about to reach the end of the lifespan thereof. As a result, the worker can identify tools that are better to be replaced now.

The search function may be used during a hiatus of the worker, for example. The hiatus includes a time period before the worker switches with the next worker, and a time period before a holiday such as a Saturday or a Sunday. The worker can efficiently perform tool replacement work by replacing not only tools that have reached the end of the lifespan thereof but also tools that are about to reach the end of the lifespan thereof, during a hiatus.

Note that the search condition that can be input is not limited to the remaining lifespan proportion. As an example, search conditions that can be input include the proportion of the amount of usage of each tool to the maximum usable amount of the tool (hereinafter also referred to as “usage amount proportion”). In this case, the information processing device5specifies a tool with an amount of usage that satisfies the search condition from among the tools specified in the tool database123.

Next, a tool transfer system10, which is an example of the aforementioned machining system1, is described with reference toFIG.2.

The following is a description of the tool transfer system10as an example of the machining system1, but the machining system1is not limited to the tool transfer system10. The machining system1need not necessarily have an automatic tool transfer function. As an example, the machining system1may be constituted by the aforementioned information processing device5and a plurality of machine tools.

FIG.2shows an outer appearance of the tool transfer system10. As shown inFIG.2, the tool transfer system10includes a workstation200, a tool storage section250, a transfer device300, and machine tools400.

The workstation200is a place where a worker performs work for tool holders. A tool holder is a pod capable of holding a tool. For example, the worker performs work to set tool holders or work to retrieve tool holders at the workstation200.

The workstation200includes an operation terminal200A. The operation terminal200A accepts various operations made to the tool transfer system10.

A plurality of tool holders may be stored in the tool storage section250. The tool storage section250functions as a temporary storage place for the tool holders.

The transfer device300transfers a designated tool holder among tool holders in the workstation200, tool holders in the tool storage section250, and tool holders in the machine tools400, to a designated transfer destination, which is one of the workstation200, the tool storage section250, and the machine tools400.

In the following, a transfer mode in which the transfer device300carries a tool holder from the workstation200to the tool storage section250or any of the machine tools400, or a transfer mode in which the transfer device300carries a tool holder from the tool storage section250to any of the machine tools400is also expressed as “to deliver”.

Further, a transfer mode in which the transfer device300carries a tool holder from the tool storage section250or any of the machine tools400to the workstation200, or a transfer mode in which the transfer device300carries a tool holder from any of the machine tools400to the tool storage section250is also expressed as “to remove (move)”.

The term “transfer device” as used herein is a concept that encompasses various devices with a function of transferring tool holders. The following description takes a four- to seven-axis drive articulated robot as an example of the transfer device300, but the transfer device300is not limited to an articulated robot. As an example, the transfer device300may alternatively be a two- or three-axis drive orthogonal robot (autoloader). Alternatively, the transfer device300may be a self-propelled robot.

The transfer device300includes an arm robot330, rails331, and a shuttle332. The arm robot330is fixed to the upper part of the shuttle332. The shuttle332is movable on the rails331. The tool storage section250and the machine tools400are arranged with the rails331therebetween and parallel with the rails331.

Each machine tool400is one of the transfer destinations, i.e. destinations to which the transfer device300transfers a tool holder.FIG.2shows six machine tools400A to400F as the machine tools400, but the number of machine tools400in the tool transfer system10need only be at least one. Each machine tool400machines a workpiece in accordance with a pre-designed machining program, using a designated tool.

The term “machine tool” as used herein is a concept that encompasses various devices with a function of machining a workpiece. The machine tool400may be a horizontal machining center or a vertical machining center. Alternatively, the machine tool400may be a lathe, an additive machine, or any other cutting or grinding machine.

Search targets on the aforementioned search screen130include tools in the tool storage section250, tools in the workstation200, and tools in the machine tool400. This allows the worker to search for tools that satisfy the search condition among the tools in the tool transfer system10.

Note that the tool transfer system10may also include a pallet transfer system (not shown). A pallet transfer system is a system for transferring pallets each carrying a workpiece to the machine tools400in accordance with a predetermined machining schedule. With this, the tool transfer system10has not only an automatic tool transfer function but also an automatic workpiece transfer function.

C. Drive Mechanism of Tool Transfer System10

Next, various drive mechanisms in the tool transfer system10are described with reference toFIG.3.FIG.3shows a configuration example of drive mechanisms of the tool transfer system10.

As shown inFIG.3, the tool transfer system10includes a controller50, a remote I/O (Input/Output) units71to73, the workstation200, the transfer device300, and the machine tool400.

The term “controller50” as used herein means a device that controls the tool transfer system10. The controller50may have any device configuration. The controller50may be constituted by a single control unit or a plurality of control units. In the example inFIG.3, the controller50includes a management device100, a PLC150, and the aforementioned operation terminal200A. The controller50may also include a CNC (Computer Numerical Control)401.

The management device100is an example of the aforementioned information processing device5. The management device100is a main computer that manages the tool transfer system10. The management device100may be constituted by a single computer or a plurality of computers.

The PLC150can communicate with various industrial devices for automating machining processes, and controls these industrial devices.

The operation terminal200A is an example of the aforementioned information processing device5. The operation terminal200A is a terminal for accepting various operations related to delivery and removal of tool holders.

The management device100, the PLC150, and the operation terminal200A are connected to a network NW1. The management device100, the PLC150, and the operation terminal200A may be communicatively connected by wire or wirelessly. The network NW1uses EtherNET (registered trademark) or the like. The management device100and the operation terminal200A send a control command to the PLC150via the network NW1. The control command specifies a tool holder to be transferred, a transfer destination of the tool holder, start/stop of transfer of the tool holder, or the like.

The remote I/O units71to73and the PLC150are connected to a network NW2. The network NW2preferably is a field network that performs periodic communication and guarantees the arrival time of data. As a field network that performs such periodic communication, EtherCAT (registered trademark), EtherNet/IP (registered trademark), CC-Link (registered trademark), CompoNet (registered trademark), or the like is adopted.

The workstation200includes at least one motor driver234and at least one motor235.FIG.3shows an example of two motor drivers234A and234B and two motors235A and235B.

The remote I/O unit71is installed in or around the workstation200. The remote I/O unit71mediates data exchange between the PLC150and various drive units (e.g. motor drivers234) in the workstation200. As an example, each of the motor drivers234receives a control command from the PLC150via the remote I/O unit71at regular periods and controls driving of a corresponding motor235in accordance with the control command.

For example, the motor235A controls driving of a later-described magazine M1(seeFIG.12), which is located in the workstation200. For example, the motor235B controls driving of an ATC (Automatic Train Control) in the workstation200.

For example, each motor driver234may be a driver for a servo motor or a driver for a stepping motor. Each motor235may be a servo motor or a stepping motor.

The transfer device300includes at least one motor driver334and at least one motor335.FIG.3shows an example of two motor drivers334A and334B and two motors335A and335B.

The remote I/O unit72is installed in or around the transfer device300. The remote I/O unit72mediates data exchange between the PLC150and various drive units (e.g. motor drivers334) in the transfer device300. As an example, each of the motor drivers334receives a control command from the PLC150via the remote I/O unit72at regular periods and controls driving of a corresponding motor335in accordance with the control command.

For example, the motor335A controls driving of the aforementioned shuttle332(seeFIG.2). For example, the motor335B controls driving of the arm robot330(seeFIG.2). The number of motors335B corresponds to the number of joints of the arm robot330.

For example, each motor driver334may be a driver for a servo motor or a driver for a stepping motor. Each motor335may be a servo motor or a stepping motor.

The machine tool400includes a CNC401, at least one motor driver411, and at least one motor412.FIG.3shows an example of two motor drivers411A and411B and two motors412A and412B.

The remote I/O unit72is installed in or around the machine tool400. The remote I/O unit72mediates data exchange between the PLC150and various drive units (e.g. CNC401) in the machine tool400. Similar to the motor drivers334, each of the motor drivers411receives a control command from the PLC150via the remote I/O unit72at regular periods and controls driving of a corresponding motor412in accordance with the control command.

For example, the motor412A drives a main shaft, to which a tool can be attached, in an axial direction of the main shaft. For example, the motor412B drives the main shaft to rotate in a rotational direction about the axial direction of the main shaft.

For example, each motor driver411may be a driver for a servo motor or a driver for a stepping motor. Each motor412may be a servo motor or a stepping motor.

D. Functional Constituents of Tool Transfer System10

Next, functional constituents for realizing processing to transfer tool holders is described with reference toFIGS.4to6.FIG.4shows an example of functional constituents of the tool transfer system10.

As shown inFIG.4, the tool transfer system10includes, as functional constituents, a monitoring unit52, a search unit54, and a transfer control unit56. These constituents are described in order below.

Note that the functional constituents may be arranged in any manner. Some or all of the functional constituents shown inFIG.4may be implemented in the aforementioned management device100(seeFIG.2), the aforementioned PLC150(seeFIG.2), the aforementioned operation terminal200A (seeFIG.2), or the aforementioned CNC401(seeFIG.2).

First, a function of the monitoring unit52shown inFIG.4is described with reference toFIG.1described above. The monitoring unit52is implemented by, for example, the aforementioned PLC150or the aforementioned CNC401.

The monitoring unit52monitors a machining program422of the machine tool400and counts the amount of usage of each tool in the machine tool400from the new state to the present. Thereafter, the monitoring unit52updates the tool database123shown inFIG.1, based on the counted amount of usage.

As an example, the machining program422for a workpiece includes a tool replacement command for designating a tool to be attached to the main shaft of the machine tool400, a drive command for rotating or feeding the main shaft or the tool, or the like. The monitoring unit52stores the identification information regarding the tool when the tool replacement command specified in the machining program422is executed. Next, the monitoring unit52starts counting the amount of usage of the tool based on the drive command specified in the machining program422being executed. Next, the monitoring unit52stops counting the amount of usage of the tool based on a stop command specified in the machining program422or a command in the last line being executed. Next, the monitoring unit52references the tool database123and adds the counted amount of usage to the current amount of usage associated with the stored identification information. Thus, the monitoring unit52regularly updates the current amount of usage of each tool.

Further, when updating the current amount of usage of each tool specified in the tool database123, the monitoring unit52also updates the remaining lifespan of each tool specified in the tool database123. Typically, the monitoring unit52updates the remaining lifespan based on the result of subtracting the current amount of usage of the tool from the maximum usable amount of the tool.

Next, a function of the search unit54shown inFIG.4is described with reference toFIG.5.

The search unit54is implemented by the aforementioned management device100or the aforementioned operation terminal200A, for example. The search unit54searches the tool database123for tool information that satisfies an input search condition, and outputs the search results.

FIG.5shows an example of a search screen130. The search screen130includes an input area131, a display field132for search results, and a retrieval button133.

The input area131accepts input of various search conditions. Input of a search condition to the input area131is realized by operating an input device, such as a mouse, or by touching the display106, for example.

The search unit54identifies tools that satisfy the input search condition among the tools specified in the tool database123, based on a search execution button131A in the input area131being pressed. Thereafter, the search unit54displays information regarding the identified tools in a display field132for the search results. The search results displayed in the display field132include, for example, identification information regarding the tools, the usable time of the tools, the current time of usage of the tools, and the remaining lifespan of the tools.

The search screen130is capable of accepting a selection operation made to each piece of the tool information displayed as search results. In the example inFIG.5, the selection operation is made to a checkbox132A. The status of the checkbox132A switches between a selected state and a non-selected state each time the worker presses the checkbox132A.

The checkboxes132A are provided according to the number of pieces of tool information displayed in the display field132for search results. Typically, the checkboxes132A are arranged next to respective pieces of tool information displayed in the display field132for search results.

Based on the retrieval button133being pressed with a checkbox132A selected, the search unit54outputs the selected piece of tool information to the transfer control unit56.

Next, a function of the transfer control unit56shown inFIG.4is described with reference toFIG.6as well asFIG.5described above.FIG.6shows an example of input to the transfer control unit56and output of the transfer control unit56in response to the input.

The transfer control unit56is implemented by the aforementioned PLC150, for example. For example, the transfer control unit56receives a machining schedule124and storage information175as input, and outputs a command to transfer a tool holder to the transfer device300.

The machining schedule124specifies, for example, a scheduled machining timing for each workpiece in each of the machine tools400, and tools used in each machining process.FIG.6shows an example of the machining schedule124for the machine tool400A.

The storage information175associates identification information regarding a tool holder stored at a storage location and identification information regarding a tool held by this tool holder with each other according to each of the storage locations where tool holders are stored in the tool transfer system10.

The storage locations specified in the storage information175are information for uniquely identifying the location of each tool holder in the tool transfer system10. As an example, each storage location indicates any of the storage location of a tool holder in the workstation200, the storage location of a tool holder in the tool storage section250, the storage location of a tool holder in the transfer device300, and the storage location of a tool holder in the machine tool400.

The identification information regarding each tool holder specified in the storage information175is information for uniquely identifying the tool holder. The identification information is assigned to each tool holder in advance. The identification information may be indicated by a tool holder number such as an ID, or a tool holder name.

The identification information regarding each tool specified in the storage information175is information for uniquely identifying the tool. The identification information is assigned to each tool in advance. The identification information may be indicated by a tool number such as an ID, or a tool name. This identification information corresponds to the identification information regarding each tool specified in the aforementioned tool database123(seeFIG.1).

The transfer control unit56references the machining schedule124and identifies the tool to be used, before the machine tool400starts machining a workpiece. Next, the transfer control unit56references the storage information175, and if the tool to be used is not present in the target machine tool400, the transfer control unit56causes the transfer device300to deliver the tool to be used from the workstation200or the tool storage section250to the target machine tool400.

Further, the transfer control unit56controls the transfer device300so as to transfer, to the workstation200, a tool corresponding to each piece of tool information selected in the display field132for search results.

The location where the tool holder to be removed is stored is identified based on the storage information175. More specifically, the transfer control unit56references the storage information175and identifies the storage location for each piece of tool information selected in the display field132for search results. The transfer control unit56then determines the tool holder holding the identified tool as a tool holder to be removed. As a result, tools that have reached the end of the lifespan thereof or tools that are about to reach the end of the lifespan thereof are removed from the tool storage section250or the machine tool400and moved to the workstation200.

Next, Variation1of search processing performed by the search unit54is described with reference toFIG.7.FIG.7schematically shows a flow of search processing according to Variation1.

The tool database123shown inFIG.1described above associates the usable time of a tool, the current time of usage of the tool, and the remaining lifespan of the tool with each other according to identification information regarding each tool. In contrast, a tool database123A according to this variation also associates information regarding properties of the tool (hereinafter also referred to as “tool property information”) according to identification information regarding each tool.

The tool property information includes, for example, an indicator of the price of a tool, an indicator of the difficulty level of measurement work for the tool, an indicator of a skill required for handling the tool, and an indicator of the importance of the tool.

The indicator of the value of a tool includes the price of the tool and classification such as high price or low price. The value of each tool may be set in advance or may be set in any manner by a user.

The indicator of the difficulty level of measurement work for a tool includes a numerical value correlated with the difficulty level, a flag indicating whether or not the measurement work is difficult, and identification information regarding a measuring instrument necessary for the measurement work. The difficulty level of each tool may be set in advance, or may be set in any manner by a user.

The indicator of a skill required for handling a tool includes a numerical value correlated with the difficulty level, and identification information regarding a worker authorized to handle the tool. The indicator of a skill for handling each tool may be set in advance, or may be set in any manner by a user.

The importance of a tool includes a numerical value correlated with the importance and a flag indicating whether or not the tool is important. The importance of each tool of each tool may be set in advance, or may be set in any manner by a user.

The search unit54accepts input of a search condition, and searches the tool database123A for tool information that satisfies the input search condition. As an example, search conditions that can be input include the remaining lifespan proportion of a tool. In this case, the search unit54searches the tool database123A for tool information indicating a remaining lifespan proportion less than or equal to the input remaining lifespan proportion. The search results are displayed in the display field132of the search screen130A. In the example inFIG.7, identification information regarding tools, the usable time of the tools, the current time of usage of the tools, the remaining lifespan of the tools, and property information regarding the tools are displayed as search results on the search screen130A.

As another example, search conditions that can be input include tool property information. As an example, if a lower limit value of the price is input as a search condition, the search unit54searches the tool database123A for tool information whose price is higher than or equal to the lower limit value. The search results are displayed in the display field132of the search screen130A. Note that the search condition may be designated by a combination of the remaining lifespan proportion of a tool and tool property information.

Next, Variation2of search processing performed by the search unit54is described with reference toFIG.8.FIG.8schematically shows a flow of search processing according to Variation2.

The tool database123shown inFIG.1associates the usable time of a tool, the current time of usage of the tool, and the remaining lifespan of the tool with each other according to identification information regarding each tool. In contrast, the tool database123B according to this variation also associates a tool classification according to the identification information regarding each tool. Tool classifications and tools pertaining to each classification are specified in advance. The tool classification includes, for example, a cutter, a reamer, and another classification name.

The search unit54accepts input of a search condition, and searches the tool database123B for tool information that satisfies this search condition. As an example, search conditions that can be input include the remaining lifespan proportion of a tool. In this case, the search unit54searches the tool database123B for tool information indicating a remaining lifespan proportion less than or equal to the input remaining lifespan proportion. The search results are displayed in a display field132of a search screen130B. In the example inFIG.8, classifications of tools, identification information regarding the tools, the usable time of the tools, the current time of usage of the tools, the remaining lifespan of the tools, and the property information regarding the tools are displayed on the search screen130B.

As another example, search conditions that can be input include a tool classification. As an example, if a tool classification is input as a search condition, the search unit54searches the tool database123B for tool information that matches the input classification, and displays the tool information on the search screen130B. Note that the search condition may be designated by a combination of the remaining lifespan proportion of a tool and a tool classification.

Next, Variation3of search processing performed by the search unit54is described with reference toFIG.9.FIG.9schematically shows a flow of search processing according to Variation3.

The search screen130shown inFIG.1displays identification information regarding tools, the usable time of the tools, the current time of usage of the tools, and the remaining lifespan of the tools as search results. In contrast, a search screen130C according to this variation also displays storage locations of the tools as search results.

More specifically, the search unit54acquires tool information that matches the input search condition from the tool database123. The search unit54then searches the storage information175for the storage location of each tool using the identification information regarding the tools specified in the tool information as a key. Subsequently, the search unit54displays information regarding the tools that match the search condition and the storage locations of the tools side by side on the search screen130C.

H. Specific Example of Search Screen130

Next, a specific example of the search screen130is described with reference toFIGS.10and11.FIG.10shows a left part of the search screen130.FIG.11shows a right part of the search screen130.

The search screen130includes the input area131for search conditions and a display field132for search results. The input area131for search conditions is constituted by input fields135A to135F.

The input field135A accepts input of a tool classification as a search condition. The tool classification is input in the form of a group number, for example.

The input field135B accepts input of a transfer status of a tool as a search condition. The transfer statuses that can be input include, for example, “Finished” indicating that transfer of the tool is complete, “Ongoing” indicating that the tool is currently being transferred, “Not yet” indicating that transfer of the tool is not yet complete, and “Unnecessary” indicating that the tool need not be transferred.

The input field135C accepts input of a tool storage location in or out of the tool storage section250as a search condition. The tool storage locations that can be input include “In CTS” indicating that the tool is stored in the tool storage section250, “Floor” indicating a different location other than the tool transfer system10, “No Data” indicating that data of the storage location of the tool is not registered, and “None” indicating that the storage location of the tool is unknown.

The input field135D accepts input of a tool storage location in or out of the machine tools400as a search condition. The tool storage locations that can be input include “All” indicating all of the machine tools400, and “MC_01”, “MC_02”, and “MC_03” indicating identification information regarding specific machine tools400.

The input field135E accepts input of the date and time range of the scheduled machining time. The date and time range is designated by either the start date and time or the end date and time.

The input field135F accepts input of a remaining lifespan condition. The remaining lifespan condition is input in the form of a combination of a numerical value and a unit, for example. The unit may be “% or less”, “% or more”, “minutes or less”, “minutes or more”, or the like. For example, if a combination of a numerical value “10” and a unit “% or less” is input as the remaining lifespan condition, the search unit54recognizes that a search condition that the remaining lifespan proportion is “10% or less” has been designated. In another example, if a combination of a numerical value “10” and a unit “minutes or less” is input, the search unit54recognizes that a search condition that the remaining lifespan proportion is “10 minutes or less” has been designated.

The search unit54searches the tool database123for tool information that matches the search condition input in the input area131, and outputs the search results in the display field132.

The display field132for search results includes a display field141related to machining schedules, and a display field142related to tool information.

In the display field141, part of or all information specified in the aforementioned machining schedule124is displayed as search results. As an example, the display field141includes a sequence number141A indicating the execution order of machining tasks, date information141B indicating a machining date, machining start information141C indicating a machining start time, identification information141D regarding a machine tool that performs machining, classification141E of a tool used in machining, and machining time information141F indicating a time required for machining.

In the display field142, part of or all information specified in the aforementioned tool database123is displayed as search results. As an example, the display field142includes amount-of-usage information142A indicating the amount by which a tool has been used in machining since the new state to the present, storage location information142B indicating the storage location of the tool, identification information142C regarding the tool, remaining lifespan information142D indicating the remaining lifespan of the tool, and142E indicating the transfer status of the tool.

I. Process of Delivering Tools to Tool Storage Section250

Next, a process of delivering a tool holder from the workstation200to the tool storage section250is described with reference toFIG.12.FIG.12schematically shows a flow of a process of delivering a tool holder from the workstation200to the tool storage section250.

In step S1, the worker sets a tool holder H1to be delivered to a magazine M1in the workstation200. The number of tool holders that can be stored in the workstation200is smaller than the number of tool holders that can be stored in the tool storage section250.

A reader device (not shown) for reading a bar code or a QR code (registered trademark) is provided near the location where the worker sets the tool holder H1to the magazine M1. The reader device reads a bar code or a QR code attached to the tool holder H1. Identification information regarding the tool holder H1to be delivered is thus read. After completing the setting of the tool holder H1, the worker performs a completion operation to the operation terminal200A.

Next, in step S2, the controller50controls the motor235A (seeFIG.3) and drives the magazine M1in the workstation200. The controller50thus moves the tool holder H1to be delivered to a predetermined tool replacement position. The ATC238is provided near the tool replacement position. The ATC238detaches the tool holder H1at the tool replacement position from the magazine M1and makes a half turn.

Next, in step S3, the arm robot330detaches the tool holder H1from the ATC238and places the tool holder H1in a temporary storage place336on the shuttle332. If there is another tool holder to be delivered, the process in steps S1to S3is repeated as long as the maximum storable number of the temporary storage place336is not exceeded.

Next, in step S4, the controller50controls the motor335A to drive the shuttle332. The controller50thus moves the shuttle332to an instructed tool delivery position. The tool delivery position is determined based on the aforementioned storage information175(seeFIG.6), for example.

The controller50references a vacant storage location specified in the storage information175and determines the storage destination of the tool holder H1. If there are a plurality of vacant storage locations, the controller50may determine, as the storage destination, one storage location randomly selected from among the plurality of vacant storage locations, or determine, as the storage destination, one storage location that is closer to the transfer device300and selected from among the plurality of vacant storage locations.

Next, in step S5, the arm robot330detaches the tool holder H1to be delivered from the temporary storage place336and stores the tool holder H1in the determined storage destination. Thereafter, the controller50updates the storage information175by associating the identification information regarding the tool holder H1with the corresponding storage location.

If another tool holder to be delivered remains in the temporary storage place336, the controller50repeats the process in steps S4and S5until no tool holder is left on the temporary storage place336.

J. Process of Delivering Tools to Machine Tool400

Next, a mode of delivering a tool holder followingFIG.12is described with reference toFIG.13.FIG.13schematically shows a flow of a process of delivering a tool holder from the tool storage section250to the machine tool400.

It is assumed that at a certain timing the controller50receives an instruction to deliver a tool holder to the machine tool400. For example, the worker designates, on the operation terminal200A, the tool to be delivered and the machine tool400that is the transfer destination. If there are more than one tool holder holding the tool designated by the worker in the tool storage section250, the controller50identifies a tool holder to be delivered. It is assumed that a tool holder H2is thus identified as a tool to be delivered. In this case, the controller50identifies the storage location of the tool holder H2from the aforementioned storage information175(seeFIG.6). Thereafter, the controller50drives the shuttle332by controlling the motor335A (seeFIG.3), and moves the shuttle332to the front of the storage location of the tool holder H2.

Next, in step S11, the arm robot330takes out the tool holder H2to be delivered from the tool storage section250and places the tool holder H2in the temporary storage place336on the shuttle332.

Next, in step S12, the controller50drives the shuttle332to the position of the machine tool400that is the delivery destination by controlling the motor335A.

Next, in step S13, the arm robot330passes the tool holder H2to the ATC438provided in the machine tool400that is the transfer destination. Thereafter, the ATC438attaches the tool holder H2received from the arm robot330to the ATC438in the machine tool400. Thereafter, the ATC438sets the tool holder H2to a magazine in the machine tool400. The tool holder H2thus becomes available in the machine tool400.

K. Process of Moving Tool to Workstation200

Next, a process of removing a tool holder is described with reference toFIG.14.FIG.14schematically shows a flow of a process of removing a tool holder from the machine tool400and moving the removed tool holder to the workstation200.

It is assumed that at a certain timing the controller50receives an instruction to retrieve a tool holder. Based on this, the controller50identifies a tool holder to be retrieved from among tool holders stored in the tool storage section250or the machine tool400. It is assumed that, as a result, a tool holder H3is identified as the tool holder to be retrieved. The controller50references the aforementioned storage information175(seeFIG.6) and identifies a storage destination of the tool holder H3. Thereafter, the controller50drives the shuttle332by controlling the aforementioned motor335A (seeFIG.3) and moves the shuttle332to the storage destination of the tool holder H3. Next, the arm robot330takes out the tool holder H3from the storage destination and places the tool holder H3in the temporary storage place336on the shuttle332. Further, the controller50deletes identification information regarding the tool holder H3from the storage information175and makes empty an entry corresponding to the storage location of the tool holder H3.

Next, in step S21, the controller50drives the shuttle332by controlling the aforementioned motor335A, and moves the shuttle332from the storage destination of the tool holder H3to the front of the workstation200.

Next, in step S22, the arm robot330detaches each tool holder H3to be removed from the temporary storage place336and attaches the tool holder H3to the aforementioned ATC238(seeFIG.12) in the workstation200. Thereafter, the ATC238attaches the tool holder H3to the magazine M1of the workstation200.

Next, in step S23, the controller50drives the magazine M1by controlling the aforementioned motor235A, and moves the tool holder H3to be removed to an exit. Thereafter, the worker takes out the tool holder H3to be removed from the exit.

L. Hardware Configuration of Management Device100

Next, a hardware configuration of the management device100shown inFIG.2is described with reference toFIG.15.FIG.15is a schematic diagram showing an example of a hardware configuration of the management device100.

The management device100includes a control circuit101, a ROM (Read Only Memory)102, a RAM (Random Access Memory)103, a communication interface104, a display interface105, an input interface107, and a storage device120. These components are connected to a bus110.

The control circuit101is constituted by at least one integrated circuit, for example. The integrated circuit may be constituted by, for example, at least one CPU (Central Processing Unit), at least one GPU (Graphics Processing Unit), at least one ASIC (Application Specific Integrated Circuit), at least one FPGA (Field Programmable Gate Array), or a combination thereof.

The control circuit101controls operation of the management device100by executing a search program122and various programs, such as an operating system. The control circuit101loads the search program122from the storage device120or the ROM102to the RAM103in response to receiving a command to execute the search program122. The RAM103functions as a working memory and temporarily stores various data necessary for executing the search program122.

A LAN (Local Area Network), an antenna, or the like is connected to the communication interface104. The management device100is connected to the network NW1via the communication interface104. With this, the management device100exchanges data with external devices connected to the network NW1. The external device includes, for example, the PLC150, a server (not shown), or the like.

A display106is connected to the display interface105. The display interface105sends an image signal for displaying an image to the display106in accordance with an instruction from the control circuit101or the like. The display106displays, for example, an operation screen for accepting an instruction to retrieve a tool holder, a selection screen for designating a tool holder to be delivered, or the like. The display106is, for example, a liquid crystal display, an organic EL (Electro Luminescence) display, or other display equipment. Note that the display106may be integrated with the management device100, or may be separate from the management device100.

An input device108is connected to the input interface107. The input device108is, for example, a mouse, a keyboard, a touch panel, or other device capable of accepting user operations. Note that the input device108may be integrated with the management device100, or may be separate from the management device100.

The storage device120is, for example, a storage medium such as a hard disk or a flash memory. The storage device120stores the search program122, the aforementioned tool database123, the aforementioned machining schedule124, or the like. The storage locations thereof are not limited to the storage device120, and may alternatively be stored in a storage area (e.g. cache memory etc.) of the control circuit101, the ROM102, the RAM103, or any other device (e.g. server, PLC150, or operation terminal200A).

The search program122is a program for realizing the aforementioned search function. The search program122may be provided not as a standalone program but as a part of any program. In this case, transfer control processing based on the search program122is realized in cooperation with that program. Even if a program that does not include such a part of a module is used, it does not deviate from the gist of the search program122according to this embodiment. Furthermore, some or all of the functions provided by the search program122may be realized by dedicated hardware. Furthermore, the management device100may be configured in a form such as a so-called cloud service in which at least one server executes a part of processing of the search program122.

M. Hardware Configuration of PLC150

Next, a hardware configuration of the PLC150shown inFIG.2is described with reference toFIG.16.FIG.16is a block diagram showing a main hardware configuration of the PLC150.

The PLC150includes a control circuit151, a ROM (Read Only Memory)152, a RAM (Random Access Memory)153, communication interfaces154and155, and a storage device170. These components are connected to a bus160.

The control circuit151is constituted by at least one integrated circuit. The integrated circuit may be constituted by, for example, at least one CPU, at least one MPU (Micro Processing Unit), at least one ASIC (application), at least one FPGA, or a combination thereof.

The control circuit151controls operations of the transfer device300and the machine tool400by executing a control program172and various programs. The control circuit151loads the control program172from the storage device170to the ROM152in response to receiving a command to execute the control program172. The RAM153functions as a working memory and temporarily stores various data necessary for executing the control program172.

A LAN, an antenna, or the like is connected to the communication interface154. The PLC150is connected to the network NW1via the communication interface154. With this, the PLC150exchanges data with an external device connected to the network NW1. The external device includes, for example, the management device100, a server (not shown), or the like.

The communication unit155is a communication interface for connection to the network NW2. The PLC150exchanges data with the external device connected to the network NW2via the communication interface155. The external device includes, for example, any of the aforementioned remote I/O units71to73.

The storage device170is, for example, a storage medium such as a hard disk or a flash memory. The storage device170stores the control program172, the aforementioned storage information175, or the like. The storage location of the control program172, the tool information174, and the storage information175is not limited to the storage device170, and may alternatively be stored in a storage area (e.g. cache memory etc.) of the control circuit151, the ROM152, the RAM153, or any other device (e.g. server).

N. Hardware Configuration of Operation Terminal200A

A hardware configuration of the operation terminal200A shown inFIG.1is described with reference toFIG.17.FIG.17is a schematic diagram showing an example of a hardware configuration of the operation terminal200A.

The operation terminal200A includes a control circuit201, a ROM202, a RAM203, a communication interface204, a display interface205, an input interface207, and a storage device220. These components are connected to a bus210.

The control circuit201is constituted by at least one integrated circuit, for example. The integrated circuit may be constituted by, for example, at least one CPU, at least one GPU, at least one ASIC, at least one FPGA, or a combination thereof.

The control circuit201controls operations of the operation terminal200A by executing a search program222and various programs such as an operating system. The control circuit201loads the search program222from the storage device220or the ROM202to the RAM203in response to receiving a command to execute the search program222. The RAM203functions as a working memory and temporarily stores various data necessary for executing the search program222.

A LAN, an antenna, or the like is connected to the communication interface204. The operation terminal200A is connected to the network NW1via the communication interface204. With this, the operation terminal200A exchanges data with an external device connected to the network NW1. The external device includes, for example, the PLC150, a server (not shown), or the like.

A display206is connected to the display interface205. The display interface205sends an image signal for displaying an image to the display206in accordance with an instruction from the control circuit201or the like. The display206displays, for example, an operation screen for accepting an instruction to retrieve a tool holder, a tool selection screen for designating a tool holder to be delivered, a machine tool selection screen for designating a machine tool400that is a delivery destination, or the like. The display206is, for example, a liquid crystal display, an organic EL display, or other display equipment. Note that the display206may be integrated with or separate from the operation terminal200A.

An input device208is connected to the input interface207. The input device208is, for example, a mouse, a keyboard, a touchscreen, or other device capable of accepting user operations. Note that the input device208may be integrated with or separate from the operation terminal200A.

The storage device220is, for example, a storage medium such as a hard disk or a flash memory. The storage device220stores the search program222or the like. The storage location of the search program222is not limited to the storage device220, and may alternatively be stored in a storage area (e.g. cache memory etc.) of the control circuit201, the ROM202, the RAM203, the management device100, the PLC150, an external device (e.g. server), or the like.

The search program222is a program for realizing the aforementioned search function. The search program222may be provided not as a standalone program but as a part of any program. In this case, transfer control processing based on the search program222is realized in cooperation with that program. Even if a program that does not include such a part of a module is used, it does not deviate from the gist of the search program222according to this embodiment. Furthermore, some or all of the functions provided by the search program222may be realized by dedicated hardware. Furthermore, the operation terminal200A may be configured in a form such as a so-called cloud service in which at least one server executes a part of processing of the search program222.

O. Tool Information Search Flow

Next, a tool information search flow is described with reference toFIG.18.FIG.18is a flowchart showing a flow of tool information search processing.

The search processing shown inFIG.18is performed by the control circuit101of the management device100executing the aforementioned search program122. Alternatively, the search processing shown inFIG.18may be realized by the control circuit201of the operation terminal200A executing the aforementioned search program222. Alternatively, a part or the entirety of the processing may be executed by a circuit element or other hardware.

In step S110, the control circuit101determines whether or not the control circuit101has accepted an operation to display the aforementioned search screen130. As an example, the control circuit101determines that the control circuit101has accepted an operation to display the search screen130based on the search program122being executed. If the control circuit101determines that the control circuit101has accepted an operation to display the search screen130(YES in step S110), the control circuit101switches control to step S112. If not (NO in step S110), the control circuit101executes processing in step S110again.

In step S112, the control circuit101causes the display106to display the search screen130for tool information. As mentioned above, the search screen130enables input of search conditions for tool information. Search conditions that can be input include, for example, a search condition related to the remaining lifespan of a tool.

In step S120, the control circuit101determines whether or not the control circuit101has accepted a search execution operation performed on the search screen130. As an example, a search execution operation is performed by pressing a search execution button131A in the search screen130. If the control circuit101determines that the control circuit101has accepted a search execution operation performed on the search screen130(YES in step S120), the control circuit101switches control to step S124. If not (NO in step S120), the control circuit101switches control to step S122.

In step S122, the control circuit101determines whether or not the control circuit101has accepted a cancel operation performed on the search screen130. As an example, a cancel operation is performed by closing the search screen130. If the control circuit101determines that the control circuit101has accepted a cancel operation performed on the search screen130(YES in step S122), the control circuit101ends the search processing shown inFIG.18. If not (NO in step S122), the control circuit101returns control to step S120.

In step S124, the control circuit101functions as the aforementioned search unit54and acquires tool information that satisfies the input search condition from the aforementioned tool database123. As an example, if the input search condition is an upper limit of the remaining lifespan proportion, the control circuit101references tool information specified in the tool database123and acquires the maximum usable amount and the remaining lifespan of each tool. Next, the control circuit101calculates the proportion of the remaining lifespan to the maximum usable amount for each tool, and searches tool information with a remaining lifespan proportion that is lower than or equal to the upper limit.

In step S126, the control circuit101functions as the aforementioned search unit54and displays the results of the search processing in step S124in the display field132of the search screen130. As mentioned above, the search screen130is capable of accepting a selection operation to select each piece of tool information displayed in the display field132. The tool corresponding to the selected piece of tool information is recognized as a tool to be retrieved.

In step S130, the control circuit101determines whether or not the control circuit101has accepted a tool retrieval operation performed on the search screen130. As an example, a tool retrieval operation is performed by pressing the retrieval button133in the search screen130. If the control circuit101determines that the control circuit101has accepted a tool retrieval operation performed on the search screen130(YES in step S130), the control circuit101switches control to step S134. If not (NO in step S130), the control circuit101switches control to step S132.

In step S132, the control circuit101determines whether or not the control circuit101has accepted a cancel operation performed on the search screen130. As an example, a cancel operation is performed by closing the search screen130. If the control circuit101determines that the control circuit101has accepted a cancel operation performed on the search screen130(YES in step S132), the control circuit101ends the search processing shown inFIG.18. If not (NO in step S132), the control circuit101returns control to step S130.

In step S134, the control circuit101outputs, to the transfer device300, a transfer command to cause the transfer device300to move each tool corresponding to the pieces of tool information selected in the search result display field to the workstation200.

As described above, the machining system1according to the embodiment accepts input of a search condition related to the remaining lifespan of a tool on the search screen130for tool information. The machining system1identifies tools whose remaining lifespan satisfies the search condition among the tools specified in the tool database123, based on the current amount of usage of each tool. Thereafter, the search screen130displays information regarding the identified tools as the search results.

The worker can search for tool information with the search condition related to the remaining lifespan by using the search function of the machining system1. This allows the worker to understand not only tools that have reached the end of the lifespan thereof but also tools that are about to reach the end of the lifespan thereof. As a result, the worker can identify tools that are better to be replaced now.

The embodiment disclosed herein is illustrative in all respects and should not be considered restrictive. The scope of the present invention is defined by the claims, rather than the above description, and intended to encompass meanings equivalent to the claims and all changes made within the scope of the claims.

LIST OF REFERENCE NUMERALS