Machine Tool Chip Removal via Image-Guided Liquid Ejection
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Solution Overview
Problem
Existing chip removal methods in machine tools require significant image processing to detect chips accurately, leading to inefficiencies and potential manual intervention, as intricate images of chips and machine tool environments complicate automated detection.
Innovation Solution
A machining system incorporating a liquid ejection unit, imaging unit, and display device that divides the captured image into mesh regions to determine chip presence and position, allowing for automated coolant ejection to remove chips without extensive image processing, using a combination of camera imaging, machine coordinate acquisition, and liquid ejection control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If huge image processing is performed to detect all chips accurately, then chip detection precision is improved, but processing time and computational resources increase significantly
Solution Approach 1:
The image processing is segmented into two stages: first, rough detection of chip regions using simplified processing; second, precise detection only within those identified regions. This segmentation allows the system to achieve high detection precision while minimizing overall processing time by applying intensive processing only where necessary.
Solution Approach 2:
The system performs partial image processing by focusing computational resources only on regions where chips are detected or suspected, rather than processing the entire image with full detail. This partial action approach maintains detection precision for chips while significantly reducing the total processing time and computational load.
2Productivity
If simple image processing is used to reduce processing time, then processing speed is improved, but chip detection accuracy deteriorates
Solution Approach 1:
The processing is divided into a fast rough detection phase that identifies potential chip regions, followed by a more accurate detection phase applied only to those specific regions. This segmentation enables the system to maintain high processing speed while ensuring accurate chip detection in the identified areas.
Solution Approach 2:
Different processing qualities are applied to different regions of the image: simplified processing for most areas and enhanced processing only where chips are detected. This local quality approach ensures high detection accuracy at chip locations while maintaining overall processing efficiency.
3Reliability
If manual chip removal is performed to ensure complete chip removal, then chip removal reliability is improved, but operational efficiency decreases
Solution Approach 1:
The system uses image processing to detect chip locations and provides feedback to control liquid ejection at those specific positions. This feedback mechanism enables automated reliable chip removal by ensuring liquid is ejected precisely where chips are located, eliminating the need for manual verification while maintaining high removal reliability.
Solution Approach 2:
The system performs self-service chip removal by automatically detecting chip positions through image processing and autonomously controlling liquid ejection to those positions. This self-service capability eliminates manual intervention, improving operational efficiency while maintaining reliable chip removal through automated detection and action.
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
Enables accurate and efficient chip removal without extensive image processing, improving operational efficiency by automating the chip removal process and reducing manual intervention.
Implementation Method 1
capture an image of the table and the workpiece
Implementation Method 2
ejecting a liquid to a related area inside the machine tool
Data Source
AI summary
There is a need for technology that enables accurate movement of chips without performing huge image processing. Provided is a display device for displaying an image captured by an imaging unit included in a machine tool. The machine tool includes a liquid ejection unit that ejects a liquid so as to move chips generated from a workpiece and the imaging unit that captures an image inside the machine tool. The display device includes: a display unit that displays the image captured by the imaging unit; a detection unit that detects an input to a predetermined position in the image displayed on the display unit; and a transmission unit that transmits an ejection signal for ejecting a liquid from the liquid ejection unit to a related area inside the machine tool related to the predetermined position, based on a detection signal according to the detection.