Adaptive Gripping Force Control for Distortion-Free Machining
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Solution Overview
Problem
Current methods for setting gripping force on workpieces during machining are burdensome and prone to errors, as they rely on experienced operators and do not account for dynamic conditions like centrifugal force during machining, leading to reduced precision and potential workpiece distortion or movement.
Innovation Solution
A gripping force adjustment device and system that utilizes a data acquisition unit, pre-processing unit, and machine learning device to adjust the gripping force based on real-time machining and workpiece data, creating a learning model to determine the optimal gripping force suitable for the specific machining conditions and workpiece state.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the gripping force of the jig is strengthened to prevent the workpiece from moving, then the workpiece may be distorted or warped by the gripping force or damaged by a chuck pawl, and as a result, the machining precision of the workpiece may deteriorate
Solution Approach 1:
The gripping force is made dynamically adjustable based on real-time machining conditions. The system continuously monitors machining parameters (cutting depth, feed rate, spindle speed) and workpiece state (vibration, position) to automatically adjust the gripping force, transitioning from a static fixed gripping force to a dynamic adaptive one that optimizes both workpiece stability and machining precision throughout the machining process.
Solution Approach 2:
The gripping force parameter is changed adaptively based on machining conditions. The system adjusts the gripping force magnitude according to real-time feedback from sensors monitoring vibration, workpiece position, and machining parameters, thereby optimizing the balance between preventing workpiece movement and avoiding workpiece distortion or damage.
2Reliability
If the gripping force is set appropriately to be strong enough not to be overcome by the cutting force but weak enough not to distort the workpiece, then an experienced operator is relied on to set the gripping force, which increases the number of operations to be performed by the operator prior to machining
Solution Approach 1:
The system performs self-adjustment of the gripping force based on real-time monitoring of machining conditions and workpiece state. The automatic control unit continuously adjusts the gripping force without operator intervention, using feedback from sensors to maintain optimal gripping force throughout the machining process, thereby eliminating the need for manual pre-setting by experienced operators.
Solution Approach 2:
The system implements closed-loop feedback control where sensors continuously monitor workpiece vibration, position, and machining parameters, and this feedback is used to automatically adjust the gripping force. The feedback mechanism enables the system to self-correct and optimize gripping force in real-time, replacing manual operator judgment with automated sensor-based control.
3Measurement precision
If the gripping force is measured while the workpiece is stationary, then the gripping force can be measured without error, but during machining using a lathe that cuts the workpiece by bringing a turning tool into contact with the workpiece while rotating the workpiece, centrifugal force and so on generated as the workpiece rotates acts on the jig, causing the gripping force to decrease
Solution Approach 1:
The gripping force measurement and adjustment system accounts for dynamic conditions during machining. Rather than relying on static measurements, the system continuously monitors and adjusts the gripping force during actual machining operations, compensating for the effects of centrifugal force and other dynamic factors that arise when the workpiece rotates.
Solution Approach 2:
The system implements real-time feedback during machining to compensate for dynamic effects. Sensors monitor workpiece position, vibration, and machining parameters during rotation, and this feedback is used to automatically adjust the gripping force to compensate for centrifugal force and other dynamic factors that reduce gripping effectiveness during machining.
Data Source
AI summary
During machining of a workpiece, a gripping force adjustment device takes into account the state of the machining and the state of the workpiece in order to set a more appropriate gripping force. The gripping force adjustment device acquires data indicating a machining state implemented by a machine tool and data relating to a gripping state realized on the workpiece by a jig, and creates data to be used in machine learning on the basis of the acquired data. The gripping force adjustment device then executes machine learning processing relating to the gripping force exerted on the workpiece by the jig in the environment in which the machine tool machines the workpiece on the basis of the created data.