Machining systems and control systems therefor

• US 4,473,883 A
• Filed: 03/26/1981
• Issued: 09/25/1984
• Est. Priority Date: 04/03/1980
• Status: Expired due to Fees

• Current Assignee: Toshiba Kikai Kabushiki Kaisha
• Original Assignee: Toshiba Kikai Kabushiki Kaisha
• Inventors: Yoshida, Tetsu, Morimoto, Isao
• Primary Examiner(s): Ruggiero, Joseph F.
• Application Number:
  US06/247,868
• Time in Patent Office: 1,279 Days
• Field of Search: 364/474, 364/475, 364/478, 364/167, 364/468, 364/469, 364/200 MS File, 364/900 MS File, 29/568, 29/564, 29/564.1, 29/564.7, 29/33 R, 29/33 P, 198/349, 198/356, 198/358, 414/134-136, 414/744, 414/753, 235/375, 235/383, 235/385
• US Class Current: 700/179
• CPC Class Codes: G05B 19/418 Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM]
• CPC Class Codes: G05B 19/4189 characterised by the transport system
• CPC Class Codes: G05B 2219/32002 Operator interface, manual control at cell, if host fails or priority
• CPC Class Codes: G05B 2219/32003 Manual control at central control to control workcell, select pallet
• CPC Class Codes: G05B 2219/32047 Workcell end instruction selects next workpiece with related program
• CPC Class Codes: G05B 2219/32048 Wait state between two successive machining steps
• CPC Class Codes: G05B 2219/32252 Scheduling production, machining, job shop
• CPC Class Codes: G05B 2219/37196 Measuring station, flexible, integrated cmm
• CPC Class Codes: G05B 2219/50099 Before restart change jig, fixture with workpieces
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
• CPC Class Codes: Y10T 483/165 Plural machine tools, e.g., flexible manufacturing

Abstract

A machining system includes machine tools each capable of performing, in a working area thereof, machining on a workpiece carried on a pallet, a pallet magazine including movable stations each capable of carrying and conveying a pallet and having pallet change positions each associated with each of the machine tools, pallet changers each associated with each of the machine tools and each capable of transferring a pallet between the working area of the associated machine tool and the associated pallet change position, numerical control devices each associated with each of the machine tools and each capable of storing part programs and of controlling the associated machine tool, and a system controller comprising first memory for storing, in relation to each of schedule numbers indicating order of machining, an indicium of a pallet carrying a workpiece to be machined in the related order and an indicium of a part program to be used for machining the related pallet, and second memory for storing, in relation to an indicium of each of the pallets, and indicium of the movable station carrying the related pallet.

Claims

1. A machining system including a plurality of machine tools each capable of performing, in a working area thereof, machining on a workpiece carried on a pallet, a pallet magazine system including a plurality of movable stations each capable of carrying and conveying a pallet and having a plurality of pallet change positions each associated with each of the machine tools, a plurality of pallet change devices each associated with each of the machine tools and each capable of transferring a pallet between the working area of the associated machine tool and the associated pallet change position, a plurality of numerical control devices each associated with each of the machine tools and each capable of storing part programs and of controlling the associated machine tool, and a system controller, said system controller comprising:

first memory means for storing, in relation to a schedule number indicating order of machining, an indicium of a pallet carrying a workpiece to be machined in the order indicated by the related schedule number and an indicium of a part program to be used for machining the related pallet, and

second memory means for storing, in relation to an indicium of each of the pallets, an indicium of the movable station carrying the related pallet.

2. A machining system according to claim 1, wherein said system controller further comprises a central processing unit which is capable of assigning, in accordance with the contents of the first memory means, a part program to be used for machining a workpiece on a pallet which has been transferred into the working area of a machine tool and instructing the associated numerical control device to start machining in accordance with the assigned part program.

3. A machining system according to claim 2, wherein each of the part programs contains an end instruction indicating completion of the machining, and said central processing unit is capable of referring, responsive to an end instruction from any of the numerical control devices, to the first memory means to determine the pallet carrying the workpiece to be machined next and the part program to be used for the next machining.

4. A machining system according to claim 3, wherein said cental processing unit is capable of referring, responsive to the indicium of the pallet carrying the workpiece to be machined next, to the second memory means to determine the movable station carrying the abovementioned pallet and of instructing the pallet magazine system to move the above-mentioned movable station and hence the above-mentioned pallet to the pallet change position associated with the numerical control device that has produced the end instruction.

5. A machining system according to claim 4, wherein each of the numerical control devices is capable of causing pallet change operation of the associated pallet change device and said central processing unit is capable of instructing, upon positioning of the pallet carrying the workpiece to be machined next to the pallet change position associated with the numerical control device that has produced the end instruction, the abovementioned numerical control device to cause the pallet change operation.

6. A machining system according to claim 2, wherein said system controller further comprises third memory means for storing in relation to the indicium of each of part programs, one or more indicia of the numerical control devices storing the related part program.

7. A machining system according to claim 6, wherein said central processing unit is capable of referring, responsive to the indicium of the part program to be used for the next machining, to said third memory means to determine whether or not the above-mentioned part program is stored in the numerical control system to be used in the next machining, and of referring, if the abovementioned part program is found not to be stored, again to the first memory means to determine, the pallet and the part program related to the schedule number of the succeeding order, the reference by said central processing unit to the first and the third memory means being repeated until the part program read out of the first memory means is found, by reference to the third memory means, to be stored in the above-mentioned numerical control device, and the instruction by the central processing unit to start machining being given only upon confirmation that the part program to be used in the next machining is stored in the numerical control device to be used in the next machining.

8. A machining system according to claim 1, wherein said system controller further comprises display means capable of displaying at least part of the contents of the first and the second memory means in the form of a table.

9. A machining system according to claim 1, wherein said system controller further comprises third memory means for storing, in relation to an indicium of each of the part programs, one or more indicia of the numerical control devices storing the related part program.

10. A machining system according to claim 9, wherein said central processing unit is capable of referring to the third memory means to ascertain that the part program to be used for the next machining is stored in the numerical control device to be used in the next machining.

11. A machining system according to claim 9, wherein said system controller further comprises display means capable of displaying, at least part of the contents of the first, the second and the third memory means in the form of a table.

12. A machining system according to claim 9, wherein indicia of the working areas of the machine tools are treated in the same way as the indicia of the movable stations.

13. A machining system according to claim 12, wherein said system controller further comprises memory means for storing the data indicating completion of machining on the respective pallets.

14. A machining system according to claim 13, wherein the data indicating the completion of the machining are stored in the memory area for storing the schedule numbers, in place of the schedule numbers.

15. A machining system according to claim 12, wherein said first memory means stores, in relation to one schedule number, a plurality of part program indicia and includes a memory area for storing the indicium of the part program to be executed next, said indicium of the part program to be performed next being incremented until all the part programs whose indicia are stored against said schedule number are completed.

16. A machining system according to claim 15, wherein said system controller further comprises a memory area for storing, in relation to each workpiece indicium, data indicating the waiting time between successive machining steps.

17. A machining system according to claim 16, wherein said memory area for storing data indicating the waiting time is provided in said first memory means.

18. A machining system according to claim 15, wherein said system controller is adapted to increment said indicium of the part program to be executed next responsive to a pallet change instruction provided at the end of each part program.

19. A control system according to claim 12, wherein said first and second memory means are adapted to update their contents responsive to an end instruction produced by any one of the machine tools.

20. A control system according to claim 19, wherein a pallet change instruction is used as the end instruction.

21. A machining system according to claim 12, wherein a pallet change instruction is used as the end instruction.

22. A machining system according to claim 12, wherein each part program contains a near end instruction in advance of a pallet change instruction, the near end instruction is used as the end instruction, and said system controller is responsive to said near end instruction for giving the pallet magazine system a drive instruction to cause positioning of the pallet corresponding to the next schedule number to said pallet change position, before completion of the machining performed in accordance with the part program whose near end instruction has been used to cause said positioning.

23. A machining system according to claim 22, wherein said system controller is adapted to give priority to the end instruction over the near end instruction concerning the positioning of the pallet, where one of the numerical control devices has given the near end instruction first and another numerical control device has given the end instruction earlier than said one of the numerical control systems.

24. A machining system according to claim 12, wherein said first memory means is adapted to store an indicium of each pallet in relation to a plurality of schedule numbers.

25. A machining system according to claim 24, wherein said first memory means is adapted to store an indicium of each part program in relation to a schedule number.

26. A machining system according to claim 25, wherein said system controller is adapted to instruct execution of a part program for the next machining step without instructing pallet change if, when one of the numerical control device has given the system controller the end instruction indicating the end of a machining step, there is another machining step succeeding the first-mentioned machining step, and a part program for the succeeding machining step is stored in the numerical control device that has given the machining end instruction.

27. A machining system according to claim 12, wherein said system controller is provided with an input device for inputting data into said first, second and third memory means.

28. A machining system according to claim 12, wherein said system controller is provided with a console unit which includes first display means associated with said first and second memory means and displaying the indicia of the movable stations and the indicia of pallets carried on the respective movable stations, and second display means indicating whether or not machining is completed on the workpieces carried on the respective pallets, whereby said first and second display means permit the operator to know which pallets are on which movable stations and whether or not machining on each pallet is completed.

29. A machining system according to claim 28, wherein said second display means comprises pushbutton switches with illuminating means, capable of being operated by the operator to assume either one of turn-on condition and turn-off condition, and said system controller is adapted to exclude the pallets when the corresponding ones of said pushbutton switches are in the predetermined one of the conditions.

30. A machining system including a plurality of machine tools each capable of performing, in a working area, machining on a workpiece carried on a pallet, a measuring unit for measuring, in a working area, a dimension of a workpiece, a pallet magazine system including a plurality of movable stations each capable of carrying and conveying a pallet and having a plurality of pallet change positions each associated with each of the machine tools and the measuring unit, a plurality of pallet change devices each associated with each of the machine tools and the measuring unit and each capable of transferring a pallet between the working area of the associated machine tool or measuring unit and the associated pallet change position of the pallet magazine system, a plurality of numerical control devices each associated with each of the machine tools and each capable of storing part programs each containing an end instruction at or near the end of the program and of controlling the associated machine tool in accordance with the part programs, a measuring unit control device capable of storing measuring programs each containing an end instruction at or near the end of the program and of controlling the measuring unit in accordance with the measuring programs, and a system controller responsive to the end instruction from any of said numerical control devices and said measuring unit device system for designating the pallet carrying a workpiece to be machined or measured next, and controlling the pallet magazine system to position the designated pallet to the pallet change position associated with the numerical control device or the measuring unit control device that has produced the end instruction, said system controller comprising:

first memory means for storing, in relation to each of the schedule numbers indicating the order of machining or measuring, an indicium of a pallet to be machined or measured in the indicated order and an indicium of a part program or a measuring program to be used for machining or measuring the related pallet, and

second memory means for storing, in relation to an indicium of each of the pallets, an indicium of the movable station carrying the related pallet.

31. A machining system according to claim 30, wherein said system controller further comprises third memory means for storing, in relation to an indicium of each of part programs and measuring programs, one or more indicia of the numerical control devices or the measuring unit control device storing the related program or measuring program, and a central processing unit which is capable of referring to the third memory means to ascertain that the part program or the measuring program to be used in the next machining or measuring is stored in the numerical control device or the measuring unit control device to be used for the next machining or measuring.

32. A machining system according to claim 31, wherein indicia of the working areas of the machine tools and the measuring unit are treated in the same way as the indicia of the movable stations.

33. A machining system including a plurality of machine tools each capable of performing, in a working area, machining of workpiece carried on a pallet, a preparation unit including a preparation station for setting a workpiece on a pallet, a pallet magazine system including a plurality of movable stations each capable of carrying and moving a pallet and having a plurality of first pallet change positions each associated with each of the machine tools and a second pallet change position associated with the preparation unit, a plurality of first pallet change devices each associated with each of the machine tools and each capable of transferring a pallet between the working area of the associated machine tool and the associated one of said first pallet change positions, a second pallet change device associated with the preparation table and capable of transferring a pallet from the preparation unit to the second pallet change position, a plurality of numerical control devices each associated with each of the machine tools and each capable of storing part programs each containing an end instruction at or near the end of the program and of controlling the associated machine tool in accordance with the part programs, a preparation unit control device capable of controlling the preparation unit for setting a workpiece on a pallet and transferring the pallet carrying the workpiece to the second pallet position, and a system controller responsive to the end instruction from any of the numerical control devices for controlling the pallet magazine system to position the pallet carrying a workpiece to be machined next to the pallet change position associated with that one of the numerical control devices which has produced the end instruction and giving said one of the numerical control devices an instruction to select, among the part programs stored in said one of the numerical systems, the part program which should be used for the next machining

said system controller comprising:

first memory means for storing, in relation to each of the schedule numbers indicating order of machining, an indicium of a pallet to be machined in the indicated order and an indicium of a part program to be used for machining the related pallet,

second memory means for storing, in relation to an indicium of each of the pallets, an indicium of the movable station or the preparation table carrying the related pallet or the working area in which the related pallet is placed, and

third memory means for storing, in rleation to an indicium of each of part programs, one or more indicia of the numerical control devices storing the related part program.

34. A machining system according to claim 33, wherein said preparation unit control device is adapted to produce a preparation end signal indicating the completion of the preparation, and said system controller is adapted to control, responsive to the preparation end signal, the pallet magazine system to position a pallet which has been excluded from the machining operation to the second pallet change position.

35. A machining system according to claim 34, wherein said preparation unit control device is provided with display means for indicating that the pallet which has been excluded from the machining has been positioned to the second pallet change position.

36. A machining system according to claim 34, wherein said system controller is adapted to provide, when the pallet which has been excluded from the machining, an instruction to said preparation unit control device to actuate the second pallet change device.

37. A machining system according to claim 34, wherein said preparation unit control device is provided with data input means for changing the contents of said first memory device including the schedule number and the indicia of the part programs concerning the pallet on which a workpiece has been set.

38. A control system according to claim 37, wherein said system controller includes a buffer register for temporarily storing data inputted by means of said data input means, and said system controller is adapted to transfer the data stored in said buffer register to said first memory means when an interrupt is permitted during the progress of the system program.

39. An operation control system for controlling a machining system including a plurality of machine tools each capable of performing, in a working area thereof, machining on a workpiece carried on a pallet, a pallet magazine system including a plurality of movable stations each capable of carrying and conveying a pallet and having a plurality of pallet change positions each associated with each of the machine tools, and a plurality of pallet change devices each associated with each of the machine tools and each capable of transferring a pallet between the working area of the associated machine tool and the associated pallet change position, each of the machine tools being associated with a numerical control device capable of storing part programs and of controlling the associated machine tool,

said operation control system comprising:

first memory means for storing, in relation to each of the schedule numbers indicating order of machining, an indicium of a pallet carrying a workpiece to be machined in the indicated order and an indicium of a part program to be used for machining the related pallet, and

second memory means for storing, in relation to an indicium of each of the pallets, an indicium of the movable station carrying the related pallet.

40. A control system according to claim 39, further comprising a central processing unit which is capable of assigning, in accordance with the contents of the first memory means, a part program to be used for machining a workpiece on a pallet which has been transferred into the working area of a machine tool and instructing the associated numerical control device to start machining in accordance with the assigned part program.

41. A control system according to claim 40, wherein each of the part programs contains an end instruction indicating completion of the machining, and said central processing unit is capable of referring, responsive to an end instruction from any of the numerical control devices, to the first memory means to determine the pallet carrying the workpiece to be machined next and the part program to be used for the next machining.

42. A control system according to claim 41, wherein said central processing unit is capable of referring, responsive to the indicium of the pallet carrying the workpiece to be machined next, to the second memory means to determine the movable station carrying the above-mentioned pallet and of instructing the pallet magazine system to move the above-mentioned movable station and hence the above-mentioned pallet to the pallet change position associated with the numerical control device that has produced the end instruction.

43. A control system according to claim 42, wherein each of the numerical control devices is capable of causing pallet change operation of the associated pallet change device and said central processing unit is capable of instructing, upon positioning of the pallet carrying the workpiece to be machined next to the pallet change position associated with the numerical control device that has produced the end instruction, the above-mentioned numerical control device to cause the pallet change operation.

44. A control system according to claim 40, further comprising third memory means for storing in relation to an indicium of each of part programs, one or more indicia of the numerical control devices storing the related part program.

45. A control system according to claim 44, wherein said central processing unit is capable of referring, responsive to the indicium of the part program to be used for the next machining, to third memory means to determine whether or not the above-mentioned part program is stored in the numerical control system to be used in the next machining, and to instruct, if the above-mentioned part program is found not to be stored, again to the first memory means to determine, the pallet and the part program related to the schedule number of the succeeding order, the reference by said central processing unit to the first and the third memory means being repeated until the part program read out of the first memory means is found, by reference to the third memory means, to be stored in the above-mentioned numerical control device, and the instruction by the central processing unit to start machining being given only upon confirmation that the part program to be used in the next machining is stored in the numerical control device to be used in the next machining.

46. A control system according to claim 39, further comprising display means capable of displaying, at least part of the contents of the first and the second memory means in the form of a table.

47. A control system according to claim 39, further comprising third memory means for storing, in relation to an indicium of each of part programs, one or more indicia of the numerical control devices storing the related part program.

48. a control system according to claim 47, wherein said central processing unit is capable of referring to the third memory means to ascertain that the part program to be used for the next machining is stored in the numerical control device to be used in the next machining.

49. A control system according to claim 47, further comprising display means capable of displaying, at least partially at a time, the contents of the first, the second and the third memory means in the form of a table.