CNC Tool Holder Collision Sensing for High-Speed Machining

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Solution Overview

Problem

Computerized machining systems, particularly CNC machines, face challenges in preventing collisions between tools and obstacles due to high spinning speeds and automatic tool changes, leading to potential damage and errors in programming.

Innovation Solution

A CNC machine equipped with a tool holder featuring a collision sensor system, including a resilient insulation layer and electrically conductive layers that connect upon impact, signaling the controller to stop the milling operation and prevent collisions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If the tool holder spins at high speed to improve productivity, then the machining efficiency increases, but the damage upon collision becomes more severe

Engineering Contradiction:

Improvemachining efficiencyVSAvoiddamage upon collision

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The patent applies beforehand cushioning by implementing a collision sensor system that detects potential collisions before they occur. The sensor includes a resilient insulation layer that deforms under impact force, providing advance warning through electrical contact between conductive layers, allowing the system to prepare for and mitigate damage before full collision occurs.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Solution Approach 2:

The patent implements feedback through a collision detection system that provides real-time information about potential collisions. The sensor system continuously monitors the tool holder's environment and feeds collision information back to the control system, enabling timely response to prevent damage while maintaining high-speed operation.

Inventive Principle:

Principle #23Feedback

2Productivity

If automatic tool change is implemented to improve productivity, then the manufacturing throughput increases, but the risk of collision due to varying tool lengths increases

Engineering Contradiction:

Improvemanufacturing throughputVSAvoidcollision risk

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent applies self-service by enabling the tool holder system to automatically detect and report collision risks without external intervention. The collision sensor system autonomously monitors tool positions and conditions, providing self-diagnosis and warning capabilities that work seamlessly with automatic tool changing operations.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent replaces mechanical collision detection methods with an electrical sensing system. Instead of relying on mechanical switches or physical contacts, the invention uses electrical conductive layers and insulation breakdown detection to sense collisions, providing more reliable and responsive detection for automated tool changing operations.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If safety margins are increased to avoid collision, then the reliability improves, but the productivity decreases due to reduced machining speed

Engineering Contradiction:

Improvecollision avoidanceVSAvoidmachining speed

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent applies preliminary action by implementing proactive collision detection before actual collision occurs. The resilient insulation layer and conductive layers are positioned to detect potential collisions in advance, allowing the system to take preventive action while maintaining normal machining speeds and safety margins.

Inventive Principle:

Principle #10Preliminary 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

The solution effectively prevents collisions and damage by ensuring timely intervention during potential collisions, enhancing the safety and reliability of CNC machining operations.

Implementation Method 1

a resilient insulation layer provided about the tool holder, and a first electrically conductive layer provided over and concentric with the resilient insulation layer

Methodology Applied

Scientific EffectMechanical deformation: Deformation

Implementation Method 2

the first electrically conductive layer is electrically-interconnected with a controller configured for stopping motion of the tool holder upon receiving a collision signal from the first electrically conductive layer

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Data Source

PatentUS20240377803A1Tool chuck arrangement for avoiding a breakage of a processing facility and methods thereof

Publication Date: 2024.11.14 FRITECH IMPORT AND MARKETING LTD

AI summary

A computer numerical control machine has a power head and a tool holder rotatable coupled to the power head. A collision sensor issues a collision signal upon detecting a collision of the tool holder with an object. The collision sensor may be in the form of thermometer measuring the temperature of the tool holder, a light sensor detecting proximity of an object to the tool holder, or a protecting sleeve mounted onto the tool holder.