Machine Tool Head Tilt Mapping for Faster CNC Calibration
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Numerical-control gantry milling machines face challenges in high-precision machining due to the time-consuming calibration process using laser detection apparatuses, which are affected by powders in the work area and require the piece-holder platform to be empty, negatively impacting productivity and precision.
Innovation Solution
A detection device comprising inclinometer sensors and an electronic control unit, temporarily fixed to the tool-carrying head, measures tilting angles and communicates with the machine's control device to create digital maps for correcting tool position and orientation, allowing for quicker calibration without the need for a laser system and enabling machining with the piece present.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If laser detection apparatus is used for calibration, then measurement precision is improved, but productivity deteriorates due to time-consuming calibration process
Solution Approach 1:
The patent replaces the optical laser detection system with a mechanical ball sensing system. The ball sensor detects the position and orientation of the calibration ball through mechanical contact, eliminating the need for laser apparatus and significantly reducing calibration time while maintaining measurement precision.
Solution Approach 2:
The patent uses a calibration ball as a physical copy/reference object that can be detected by the ball sensor. The ball serves as a simplified representation of the tool center point, allowing for quick and accurate calibration without complex laser scanning procedures.
2Measurement precision
If laser detection apparatus is used for calibration, then measurement precision is improved, but ease of operation deteriorates due to requirement of empty piece-holder platform
Solution Approach 1:
The mechanical ball sensor system allows calibration to be performed with the workpiece present on the platform, as the sensor detects the calibration ball through direct mechanical contact rather than optical line-of-sight requirements. This eliminates the operational constraint of requiring an empty platform.
3Measurement precision
If laser detection apparatus is used for calibration, then measurement precision is improved, but reliability deteriorates due to interference from powders in work area
Solution Approach 1:
The patent replaces the optical laser detection system with a mechanical ball sensor system that is insensitive to environmental factors such as powders, chips, and other contaminants in the work area. The mechanical contact-based detection method ensures reliable calibration measurements regardless of airborne particles.
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 method significantly reduces calibration time, allows for precise machining with the piece present, and enhances productivity by using a non-laser based calibration system that is less affected by environmental factors.
Implementation Method 1
measuring, in successive control points of a same detection plane, values of tilting of said tool vector associated with said detection device, relative to a predetermined reference inertial plane
Data Source
AI summary
An operating method of a numerical-control machine tool characterized in that it comprises the steps of providing the tool-carrying head of the numerical-control machine tool with a detection device adapted to measure the values of the tilting of the detection device relative to a predetermined reference inertial plane; and moving the tool-carrying head in space so as to place said detection device in succession in a multitude of control points distributed on a first detection plane, and create at least a first digital map that contains the tilting values of the detection device relative to the reference inertial plane, in each of said control points.