The main applications of Mazak's machine vision technology in Japan are as follows:
(1) Identification of the workpiece The workpiece conveyed by the pallet is identified, and then the corresponding programming software is called for processing.
(2) Automatic measurement of the workpiece The infrared measurement of each dimension of the machined part is carried out. According to the measurement result, it is judged whether the part is qualified, and the necessary parameters of the machine tool are compensated to ensure the pass rate of the batch part.
(3) Tool detection When the tool is automatically changed from the tool magazine to the spindle, the damage of the tool can be detected by infrared scanning. If the tool is damaged, the spare tool is automatically called to ensure the stability of the processed product.
(4) Thermal displacement compensation The temperature of each part of the machine tool is detected by the thermal element mounted on the machine tool and compensated according to the measurement result. The machine tool can maintain good precision regardless of the external environment temperature and the temperature of the machine tool itself.
3. Flexible fixture technology
The flexible fixture refers to the strain capacity of the fixture after a certain change in the shape and size of the workpiece. With the development of the manufacturing industry, more and more varieties of production, so that the manufacturing system must be able to quickly respond to product changes, in order to shorten the product design and manufacturing cycle, increase the flexibility of the manufacturing system, reduce costs, improve product quality, not just The machine has a flexible function and also requires the corresponding product fixture to have this function.
Mazak's flexible fixtures are designed to accommodate a wide variety of unmanned production. If the processed product changes, the corresponding soft claw (SOFT-JAW) can be found by the robot to the soft claw library, and the quick change can be performed, thereby improving the processing efficiency and realizing the unmanned operation.
The latest development in flexible fixtures is to address the challenge of "positioning-processing". Conceptually, "seeking-machining" is a large-scale workpiece locating algorithm and computer means using image and sensing technology, artificial intelligence, to solve the actual posture and position of the workpiece, and then use the strict procedure without the need to preset Based on the feedback information after the workpiece is searched, the tool motion path and the trajectory are generated in real time to realize the machining of the workpiece. "Finding-machining" simply does not require positioning, and clamping is still necessary and cannot be omitted.
Multi-variety high-volume manufacturing system Multi-variety high-volume manufacturing system is a new auto parts manufacturing system in the era of diversification, and is the latest technological innovation in manufacturing technology to meet the diversity and economic requirements. For example, for professional transmission plants and engine heads, due to the requirements of different users, it is necessary to provide a multi-variety variable-volume manufacturing system of medium-sized and weight transmission housings and engine cylinder heads.
At present, many companies still use a large number of general-purpose machining centers and CNC machine tools to complete multi-variety high-volume manufacturing tasks, which is the most backward manufacturing system. More advanced is the use of composite machine tools. When the author visited Germany in 2009, DMG demonstrated the machining of a large-displacement aluminum alloy transmission housing with a compound turning and milling center, all of which took less than 10 minutes. This is probably the highest efficiency to date. However, it still cannot meet the large number of manufacturing requirements of many varieties.
Meet multi-variety mass production systems
The required machine tool has just begun to develop, and there are not many successful cases. In recent years, several subversive innovation cases have emerged in the world, and they have brought about a new revolution in the way machine tools move. So far only two German companies have provided proven technology, but only for multi-variety mass production of small and complex parts. One is the XG series machining center developed by Ex-Cell-O in Germany and has the characteristics of combined machine tools and machining centers. The second is the compact flexible automatic assembly line of Witzig & Frank in Germany (see below).
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