Tool Setting Beam Profile Assessment for Contamination Drift
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Solution Overview
Problem
Non-contact tool setting apparatus in dirty machine tool environments face reduced measurement accuracy due to beam width changes caused by contaminants and thermal growth, requiring frequent maintenance and increasing downtime.
Innovation Solution
A method and apparatus for assessing the beam profile of a non-contact tool setting apparatus by determining the beam width using a transmitter and receiver, where an object with an edge is moved through the light beam, and the beam intensity signal is analyzed to characterize the beam profile, allowing for regular checks without disrupting production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If non-contact tool setting apparatus is used in dirty machine tool environments, then tool setting functionality is provided, but measurement accuracy deteriorates due to beam width changes caused by contaminants and thermal growth
Solution Approach 1:
The patent applies preliminary action by measuring the beam profile at the beginning of the machining process and before tool measurements are taken. This advance measurement allows the system to establish a reference beam profile and detect any changes that may have occurred during operation, enabling compensation for beam width changes before they affect measurement accuracy.
Solution Approach 2:
The patent applies parameter changes by monitoring variations in beam profile parameters (such as beam width and shape) and using this information to adjust or compensate for changes in measurement conditions. The system detects parameter changes in the beam profile caused by thermal growth or contaminants and uses these changes to correct measurement results, maintaining accuracy despite environmental factors.
2Reliability
If regular maintenance cleaning is performed to remove contaminants, then measurement accuracy is improved, but machine tool downtime increases
Solution Approach 1:
The patent replaces the mechanical cleaning system with an optical detection system. Instead of physically cleaning the apparatus to maintain accuracy, the system uses optical beam profile measurements to detect and compensate for the effects of contaminants. This substitution eliminates the need for downtime-consuming cleaning operations while maintaining measurement accuracy through software-based compensation.
Solution Approach 2:
The system applies self-service by automatically detecting beam profile changes and performing compensation calculations without requiring external intervention or manual cleaning. The apparatus monitors its own performance and adjusts for degradation caused by contaminants, enabling continuous operation without maintenance downtime.
3Reliability
If beam profile changes are monitored frequently to maintain accuracy, then measurement reliability is improved, but productivity decreases due to increased measurement time
Solution Approach 1:
The patent applies partial action by measuring only the critical parameters of the beam profile (such as beam width at specific intensity levels) rather than performing complete beam characterization. The system uses simplified measurement approaches that capture the essential changes needed for compensation without the full overhead of comprehensive beam analysis, thus maintaining accuracy while reducing measurement time.
Solution Approach 2:
The system applies universality by designing the beam profile measurement system to serve multiple functions: it characterizes the beam for accurate tool measurements, detects changes due to thermal growth or contaminants, and provides data for compensation calculations. This multi-functionality allows a single measurement process to support multiple objectives, improving reliability without proportionally increasing measurement time.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables quick and accurate measurement of beam width, reducing the need for frequent maintenance and minimizing downtime by allowing for regular checks of beam profile changes, ensuring consistent measurement accuracy.
Implementation Method 1
a light source which generates a beam of light which is passed to a detector
Implementation Method 2
The receiver detects (e.g. using a photodiode) the received light and generates a beam intensity signal describing the intensity of the received light
Data Source
AI summary
A method assesses the beam profile of a light beam of a non-contact tool setting apparatus, the apparatus including a transmitter for emitting the light beam and a receiver for receiving the light beam. The receiver generates a beam intensity signal describing the intensity of received light. The apparatus is mounted to a machine tool having a spindle that is moveable relative to the non-contact tool setting apparatus. The method includes loading an object having an edge into the spindle of the machine tool and using the machine tool to move the spindle relative to the apparatus so that the edge of the object passes through the light beam. The beam profile of the light beam is then determined using the beam intensity signal generated at a plurality of positions during the step (ii) of moving the edge of the object through the light beam.