Chuck Body Deformation Sensor for Clamping Force Monitoring
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Solution Overview
Problem
Chucks used in machining processes face issues with maintaining a minimum clamping force over time due to contamination and high temperatures, leading to inefficient maintenance schedules and potential loss of clamping force.
Innovation Solution
A chuck body with a deformation sensor, typically rotationally symmetric, is equipped to measure circumferential deformation, allowing for precise determination of clamping force without disassembly, using strain gauges and wireless signal transmission for easy access and maintenance, and incorporating energy harvesting and storage for autonomous operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the chuck is maintained after a predetermined number of machining cycles, then the clamping force can be restored to minimum levels, but maintenance may be performed unnecessarily early under favorable ambient conditions or too late under unfavorable conditions
Solution Approach 1:
The patent implements a feedback mechanism by equipping the chuck body with a deformation sensor that continuously monitors the actual clamping force. The sensor detects deformation of the chuck body and converts it into electrical signals that are evaluated by a control device. When the clamping force drops below a predetermined minimum value, the control device automatically triggers a maintenance signal, enabling condition-based maintenance rather than time-based maintenance. This resolves the contradiction by performing maintenance only when actually needed, reducing unnecessary downtime while ensuring reliability is maintained.
2Measurement precision
If deformation sensors and signal transmission devices are integrated into the chuck body, then real-time clamping force monitoring is enabled, but the device complexity increases
Solution Approach 1:
The patent replaces complex mechanical measurement systems with a more integrated sensor-based approach. Instead of using mechanical indicators or external measurement devices, the invention integrates deformation sensors directly into the chuck body structure. These sensors electrically detect deformation and convert it into measurable signals. The control device then evaluates these signals to determine clamping force. This substitution of mechanical measurement with electrical sensing reduces overall system complexity while improving measurement precision and enabling continuous monitoring.
3Stability of the object's composition
If the chuck body is designed to be substantially rotationally symmetric for force transfer, then the structural integrity is maintained, but the integration of sensors and the basic body design becomes more challenging
Solution Approach 1:
The patent applies the local quality principle by integrating sensors at specific strategic locations on the chuck body rather than requiring complete redesign of the entire rotationally symmetric structure. The deformation sensors are positioned to detect radial deformation of the chuck body, which is then used to calculate clamping force. This localized sensor integration maintains the overall rotational symmetry and structural integrity of the chuck body while enabling measurement functionality. The control device processes the local deformation data to determine overall clamping force, thus preserving manufacturing simplicity while achieving measurement capability.
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 cycle-independent, as-needed maintenance of chucks by providing real-time clamping force data, reducing downtime and extending the operational life of machining tools by ensuring consistent clamping forces.
Implementation Method 1
the deformation sensor as a strain gauge is constructed with strain or extension-dependent electrical resistance
Implementation Method 2
with the basic body is associated a coil mechanism for an energy conversion according to the dynamo principle for making available electrical energy for the deformation sensor
Implementation Method 3
the friction between the clamping head and chuck body, which is determined by external circumstances such as contamination and/or gumming up of the lubricant between clamping head and chuck body
Implementation Method 4
During said wedging movement on the one hand the desired narrowing of the free diameter between the clamping jaws of the clamping head is brought about
Data Source
AI summary
A chuck body for a clamping chuck for clamping a workpiece has a substantially rotationally symmetrically formed basic body, provided on which is a receiving opening, which is formed as a portion of a cone and is formed for receiving a clamping head in such a way as to transmit force. Attached to the basic body is a deformation sensor, for example as a strain gauge, which is intended and designed for determining a deformation of the basic body in a circumferential direction. In this way, the condition and state of wear of the clamping chuck can be determined.