Intelligent laser-based depth and feed control system for planing machines

Abstract

An intelligent laser-based depth and feed control system for planing machines, consisting of a laser distance sensor, a vibration sensor and a motor current sensor, configured to monitor the machining parameters in real time and transmit data to a control unit.

Description

Application area of ​​the invention

[0001] The present invention relates to the field of automation and control of machine tools, in particular an intelligent laser-based device for monitoring, adjusting and optimizing the cutting depth and feed rate in planing machines to improve accuracy, safety and efficiency in metalworking operations. Background of the invention

[0002] Conventional broaching machines, while widely used in metalworking and surface finishing, rely heavily on operator experience when setting cutting depth and feed rate. Incorrect parameter selection often leads to excessive tool wear, poor surface finish, vibration-induced inaccuracies, and even mechanical damage. Conventional systems lack adaptive monitoring mechanisms capable of detecting fluctuations in cutting forces or workpiece irregularities in real time. Furthermore, operator safety and training are often hampered by the lack of real-time feedback or automated interventions. While the integration of digital sensors and intelligent monitoring systems in machining has made significant progress, most existing solutions are tailored to CNC systems and are not compatible with conventional broaching machines.There is an urgent need for a system that combines cost-efficiency, simplicity, and intelligence, and can dynamically adapt machining parameters to the prevailing conditions in real time. Such a system should increase operational reliability, improve machining accuracy, and extend the service life of both tools and machines, and be suitable for both industrial and training environments. Summary of the invention

[0003] The present invention describes an intelligent, laser-based system for depth and feed control in planing machines. It integrates laser distance measurement, vibration detection, and motor current monitoring for real-time feedback and adaptive control. Using a laser sensor, the system determines a precise zero point and continuously measures the cutting depth during machining. Simultaneously, vibration and current sensors monitor mechanical stability and cutting force, respectively. The sensor data is processed by a microcontroller or a programmable logic controller (PLC), which compares the measured values ​​with predefined safety limits stored in a material-specific database.

[0004] The system features an intuitive user interface for parameter input and guided operation. It offers various operating modes, including automatic control, training support, and manual intervention for experienced operators, making it suitable for users of varying skill levels. Audible and visual alarms, along with an emergency stop mechanism, prevent unsafe operating conditions. Thanks to its retrofit compatibility, the system can be integrated into both new and existing planing machines. The system's adaptive intelligence reduces tool wear, improves surface finish, and increases sustainability through minimal resource consumption and reduced downtime. Detailed description

[0005] The invention comprises a compact, sensor-integrated monitoring unit for mounting on a conventional planer. The laser distance sensor, positioned near the cutting tool, determines the precise distance between the tool tip and the workpiece surface, thus establishing a zero point before the machining process. During tool movement, continuous laser measurements provide real-time data on the cutting depth. A vibration sensor mounted on the tool head or ram detects mechanical vibrations, enabling the detection of chatter or instabilities during machining.

[0006] A motor current sensor connected to the planer's drive motor monitors current fluctuations to determine the cutting force in real time. All sensor data is transmitted to a central processing unit (e.g., a microcontroller or a PLC) responsible for data fusion and analysis. This unit compares the measured values ​​with safe operating limits stored in an integrated database, based on material type, tool geometry, and machining conditions.

[0007] If parameters exceed safe limits, the control system issues warning messages via an audiovisual signal module and prompts the operator to adjust settings or interrupt operation. In extreme situations, an automatic emergency stop mechanism is triggered to protect the machine and operator. The user interface consists of a touchscreen or a digital control panel, allowing operators to select materials, enter tool specifications, or choose preconfigured settings.

[0008] In training mode, the system provides step-by-step visual and audible instructions, helping inexperienced users understand optimal processing parameters. In expert mode, it intervenes only minimally but continues to monitor safety limits. A data logging function records process parameters, enabling performance analysis and predictive maintenance planning.

[0009] Thanks to modular sensor mounts and standardized communication interfaces, the system can be retrofitted to existing form milling machines without major mechanical modifications. It can also be integrated into newly manufactured machines as part of an intelligent industrial control architecture. Laser and sensor modules are protected in robust housings, making them resistant to the demands of industrial environments and ensuring durability and reliability.

[0010] Communication between sensors and control units can be wired or wireless, depending on the installation conditions. The firmware supports calibration routines for various tool types and workpiece geometries, thus ensuring consistent accuracy. Power is supplied either via the machine's existing electrical system or, for safety reasons, via a separate low-voltage supply.

[0011] By integrating intelligent sensors and control technology, the invention significantly increases operational precision, minimizes tool failures, and improves surface quality. It also supports sustainable manufacturing methods through optimized energy consumption and extended tool life.

Claims

[1] An intelligent laser-based depth and feed control system for planing machines, consisting of a laser distance sensor, a vibration sensor and a motor current sensor, configured to monitor the machining parameters in real time and transmit data to a control unit. [2] System according to claim 1, wherein the control unit comprises a microcontroller or PLC programmed to compare real-time sensor data with predefined safe operating thresholds stored in a material and tool database to control the machining conditions. [3] System according to claim 1, wherein the user interface enables the selection of the material type and the input of processing parameters and provides audiovisual feedback, training instructions and an emergency stop function. [4] System according to claim 1, wherein the device is configured as a retrofit module or integrated system that can be adapted to conventional and modern molding machines to ensure higher precision, safety and sustainability.