Backlash Detection via Servo Reciprocation and Sensor Feedback
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Solution Overview
Problem
Current methods for detecting backlash errors in machine tools are inefficient and costly, requiring extensive time and labor, especially when using laser interferometers, which increase equipment costs and are not suitable for real-time precision adjustments.
Innovation Solution
A backlash automatic detection system and method that utilizes a control device to output commands to a servo driver, allowing the nut seat to move in reciprocating directions, defining a backlash phenomenon period and displacement as a backlash value without the need for external detectors like laser interferometers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If laser interferometer is used for backlash detection, then measurement precision is improved, but device complexity and cost increase
Solution Approach 1:
The patent replaces the optical laser interferometer system with a mechanical sensor-based detection system. The sensor detects positional information of the moving component, and the control unit calculates backlash based on this mechanical/electrical signal, eliminating the need for complex optical equipment while maintaining detection capability.
Solution Approach 2:
The patent uses simple, low-cost position sensors instead of expensive laser interferometers. These sensors are relatively inexpensive components that can be easily replaced or recalibrated, providing an economical alternative to high-precision optical measurement equipment.
2Measurement precision
If laser interferometer is used for backlash detection, then measurement precision is improved, but loss of time increases
Solution Approach 1:
The mechanical sensor system enables faster data acquisition compared to optical interferometry. The sensor directly measures position without requiring complex optical path setup, and the control unit immediately processes the signals to calculate backlash, significantly reducing the overall detection time.
Solution Approach 2:
The system performs automatic backlash detection and calculation without requiring operator intervention for setup or measurement. The control unit automatically processes sensor data and computes backlash values, eliminating manual operations and reducing time loss.
3Measurement precision
If conventional detection method is used, then measurement precision is maintained, but productivity decreases
Solution Approach 1:
The automated sensor-based system replaces manual or semi-automatic detection methods, enabling continuous operation and faster throughput. The system can perform multiple measurements rapidly and automatically, significantly improving detection productivity while maintaining precision through controlled measurement procedures.
Solution Approach 2:
The system enables continuous backlash detection during machine operation or in rapid succession, rather than requiring lengthy setup and measurement cycles. The automated nature allows for uninterrupted detection operations, improving overall productivity.
4Device complexity
If simple detection method is used, then device complexity is reduced, but measurement precision deteriorates
Solution Approach 1:
The control unit uses feedback from the position sensor to accurately determine backlash values. By continuously monitoring sensor signals and processing them through calculated algorithms, the system achieves precise measurements despite using simple hardware, compensating for potential measurement errors through computational methods.
Solution Approach 2:
The control unit acts as an intermediary that processes raw sensor data and transforms it into accurate backlash measurements. This computational intermediary layer enables simple sensors to achieve the precision of complex optical systems through intelligent signal processing and calculation algorithms.
Data Source
AI summary
A backlash automatic detection system comprises a control device and a machine tool. The machine tool comprises a servo driver, a lead screw, a nut seat and a platform. The method comprises: entering an initial state and outputting a control command to the servo driver through the control device; driving the lead screw by the servo driver to move the nut seat towards a first direction and changing the movement direction of the nut seat towards a reverse second direction by the servo driver; defining a backlash phenomenon period according to one time point at which the nut seat starts to move towards the second direction and another time point at which the platform is driven to move by the nut seat; defining the displacement of the nut seat corresponding to the backlash phenomenon period as a backlash value.