Machine Tool Wear Diagnosis Through Load-Position Tolerance Checks
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Solution Overview
Problem
Machine tool machining accuracy deteriorates over time, requiring frequent replacement of wear-prone components, which is costly and inefficient.
Innovation Solution
A method that identifies specific components causing wear by performing tolerance measurements at different load positions on the machine tool's working axes, allowing for targeted maintenance instead of replacing all worn parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If tolerance measurements are performed at multiple positions with different load values, then wear can be assigned to specific components, but the measurement and analysis complexity increases
Solution Approach 1:
The patent segments the machine tool components into groups based on their load characteristics and positions. By dividing the components into wear-prone groups and non-wear-prone groups, the system can focus measurements on specific segments, improving wear detection precision without requiring complex system-wide measurements.
Solution Approach 2:
The patent applies local quality by performing tolerance measurements at specific positions with different load values rather than uniformly across all components. This localized measurement approach allows precise wear assignment to specific components while avoiding unnecessary measurements elsewhere, reducing overall system complexity.
2Manufacturing precision
If all wear-prone components are replaced to restore tolerances, then machining accuracy is restored, but operating costs increase
Solution Approach 1:
The patent extracts only the specific components that are actually causing wear and tolerance deviations, rather than replacing all wear-prone components. By identifying and isolating the problematic components through load-based analysis, the system restores machining accuracy while avoiding the unnecessary replacement of other components, thereby reducing operating costs.
Solution Approach 2:
The patent enables selective discarding of only those components that have actually worn beyond acceptable tolerances, while recovering and continuing to use other components that are still within tolerance. This selective approach maintains machining precision while minimizing waste and operating costs.
3Ease of operation
If random samples of workpieces are used to check tolerances, then wear detection is simple, but the precision of wear assignment is reduced
Solution Approach 1:
The patent performs preliminary tolerance measurements at multiple positions with different load values before making wear assignments. This preliminary action of collecting comprehensive measurement data from various load conditions enables precise wear assignment to specific components while maintaining operational simplicity through automated analysis.
Solution Approach 2:
The patent uses feedback from tolerance measurements at different load positions to continuously refine wear assignments. By comparing measurement results across multiple positions and using this feedback to identify patterns, the system achieves precise wear assignment while keeping the operation simple through automated feedback-driven analysis.
Data Source
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AI summary
A method for controlling a machine tool comprising the steps of: providing a data memory containing a plurality of data tuples for at least one specific working axis of the multiple working axes, each tuple assigning a load value to a position value relative to the specific working axis; selecting a first data tuple and a second data tuple whose load values are different; and generating at least one control command for the machine tool, wherein the control command is configured to perform a first tolerance measurement at a first position value and a second tolerance measurement at a second position value, and wherein, based on a first result of the first tolerance measurement and a second result of the second tolerance measurement, information about the wear of a part of the machine tool is output. Furthermore, a corresponding device is disclosed.