Break-Beam Tool Profiling for Faster Non-Contact Edge Measurement
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing non-contact tool setting apparatuses for coordinate positioning systems are inefficient in measuring the profile of tools, as they require repetitive movement of the tool in and out of a light beam, making the process time-consuming and impractical for detailed measurements.
Innovation Solution
A method and apparatus that use a light beam traced along the periphery of a tool, combined with a coordinate positioning system, to collect and analyze beam intensity data, allowing for quick and detailed profiling of tool shapes and dimensions by moving the light beam tangentially to the tool edge, rather than perpendicularly, and utilizing digital signal processing to identify minima and maxima for rotating tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the tool is moved repeatedly into and out of the light beam to measure multiple points on the tool edge, then the tool profile can be measured, but the measurement process becomes very time-consuming
Solution Approach 1:
The patent replaces the mechanical approach of moving the tool repeatedly into and out of the beam with an optical scanning system. The light beam is scanned along the periphery of the tool using a coordinate positioning apparatus, allowing continuous profiling without repetitive mechanical movements. This substitution of mechanical measurement with optical scanning resolves the contradiction by enabling complete profile measurement in a single pass.
Solution Approach 2:
The patent transitions from one-dimensional point measurements (moving tool in and out of beam) to two-dimensional periphery scanning. By scanning the light beam along the tool periphery in a tangential direction, the system captures profile data across multiple dimensions simultaneously, enabling complete profile assessment without repeated measurements.
2Productivity
If the light beam is moved along the periphery of the tool to trace the tool edge, then the measurement speed increases, but the complexity of positioning and scanning increases
Solution Approach 1:
The patent utilizes the existing coordinate positioning apparatus, already present in machine tools for tool movement, to perform the additional function of beam scanning and profile measurement. This multi-functional use of the positioning system increases measurement speed without requiring entirely new hardware, thereby limiting the increase in overall system complexity.
Solution Approach 2:
The patent introduces a digital processor as an intermediary that receives beam intensity data and automatically performs the complex tasks of data analysis, profile reconstruction, and deviation calculation. This intermediary handles the computational complexity, allowing the physical scanning system to remain relatively simple while achieving high measurement speeds.
3Loss of information
If multiple measurement moves are performed to capture different points on the tool edge, then complete profile data is obtained, but the process becomes impractical for detailed measurements
Solution Approach 1:
The patent implements continuous scanning of the light beam along the tool periphery in a single uninterrupted motion. This continuous action captures complete profile data without the need for multiple discrete measurement moves, making the process practical for detailed measurements while ensuring no profile information is lost.
Solution Approach 2:
The patent creates a digital copy of the tool profile by measuring the light beam intensity variations as it scans along the periphery. This digital representation captures the complete profile information in a single pass, eliminating the need for physical repetitive measurements and making detailed profiling practical and efficient.
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 significantly reduces the time and complexity of tool profiling, enabling quicker and more accurate measurements of tool profiles, including deviations from nominal specifications, and allows for separate assessment of cutting teeth, improving measurement efficiency and precision.
Implementation Method 1
a transmitter for emitting a light beam and a receiver for receiving the light beam
Implementation Method 2
the receiver generating a beam intensity signal describing the intensity of received light
Data Source
AI summary
A method for assessing the profile of a tool using a non-contact tool setting apparatus that includes a transmitter for emitting a light beam and a receiver for receiving the beam. The receiver generates a beam intensity signal describing the intensity of received light. The setting apparatus is mounted to a coordinate positioning apparatus that allows the tool to be moved relative to the setting apparatus. The method includes using the coordinate positioning apparatus to move the tool relative to the setting apparatus along a tool inspection path, the tool inspection path being selected so that the light beam is traced substantially along a periphery of the tool to be inspected. Beam intensity data is collected describing the beam intensity signal that is generated by the receiver as the tool inspection path is traversed and analysis of the collected beam intensity data is used to assess the tool profile.