CNC Tool Damage Detection via Torque Signal Simulation
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Solution Overview
Problem
Existing methods for detecting tool damage in CNC machines are limited in recognizing gradual tool abrasion and distinguishing it from changes in processing conditions, making them unsuitable for varied machining operations, and are not applicable for safe unmanned processing.
Innovation Solution
An apparatus using a 3-dimensional simulator, tool manager, and database to predict processing conditions and detect tool damage by analyzing torque signals from a servo and spindle, allowing for real-time adjustment of processing parameters to prevent tool damage and provide warnings or stop operations as necessary.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If current signal monitoring method is used to detect tool damage, then additional measuring devices are not required, but it is impossible to distinguish between tool abrasion and changes in processing conditions
Solution Approach 1:
The patent segments the detection process into multiple independent components: a simulator that predicts torque under normal conditions, a detector that monitors actual torque, and a comparator that identifies deviations. This segmentation allows the system to distinguish between expected torque variations and actual tool damage without requiring complex additional sensors.
Solution Approach 2:
The patent introduces a simulator as an intermediary component that generates predicted torque values based on processing conditions. This intermediary serves as a reference model that mediates between the raw current signals and the damage detection logic, enabling accurate distinction between normal variations and actual damage.
2Extent of automation
If traditional tool lifespan management is used, then tool exchange is automated based on predetermined use time, but it is not applicable to varied machining operations with different shapes
Solution Approach 1:
The patent transitions from static, time-based tool management to dynamic, condition-based management. The simulator continuously adapts to varying processing conditions by predicting torque based on actual machining parameters, allowing the system to automatically adjust detection thresholds for different workpiece shapes and operations while maintaining full automation.
3Device complexity
If torque monitoring is performed without prediction capability, then simple current signal comparison is possible, but changes in torque cannot be recognized as tool abrasion or processing condition changes
Solution Approach 1:
The patent applies preliminary action by having the simulator predict expected torque values before actual machining occurs. This prediction is based on processing conditions and serves as a reference that prevents information loss during comparison, enabling the system to recognize whether torque changes are due to tool abrasion or normal processing variations.
Data Source
AI summary
The apparatus for detecting damage to the tool in the machine and the method of detecting damage to the tool according to the present disclosure are applied to a machine, such as a CNC, to detect and control damage to a tool and possibility of damage in advance, thereby efficiently managing processing work by the machine while achieving safety of the machine.