Numerical Controller Tool Life Management via Dynamic Consumption Factors
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Solution Overview
Problem
Existing numerical controllers fail to accurately manage tool life during machining due to changes in machining conditions such as coolant concentration, pH, and temperature, leading to unexpected tool life exhaustion.
Innovation Solution
A numerical controller that includes a tool data storage section, machining condition data storage section, and sections for calculating tool usage and consumption factors, allowing real-time adjustment of tool life based on current machining conditions, enabling selection of tools with sufficient life and safe operation stop when tool life is expected to end.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If tool life is estimated based on machining conditions before machining starts, then the operator can prepare a tool with sufficient life in the tool magazine, but the tool life may end unexpectedly during machining when machining conditions change
Solution Approach 1:
The patent implements a feedback mechanism by continuously monitoring actual machining conditions (coolant concentration, pH, temperature) during machining and using this information to recalculate consumption factors and accumulated consumption life. This closed-loop feedback system allows the controller to adjust tool life management dynamically, preventing unexpected tool life exhaustion by responding to real-time condition changes.
Solution Approach 2:
The system transitions from static tool life estimation (based on pre-machining conditions) to dynamic tool life management by continuously updating consumption factors based on actual machining conditions. The controller dynamically recalculates accumulated consumption life at each block, enabling adaptive tool selection and management that responds to changing machining environments.
2Reliability
If machining conditions change during operation, then the consumption factor changes causing tool life to be consumed faster than estimated, but continuously monitoring and recalculating increases system complexity
Solution Approach 1:
The patent applies preliminary action by pre-storing consumption factor data for various machining conditions in a database before machining begins. When actual conditions are detected during machining, the controller simply retrieves the appropriate consumption factor from the pre-prepared database rather than performing complex real-time calculations, thereby reducing computational complexity while maintaining accuracy.
Solution Approach 2:
The system replaces complex real-time mathematical modeling and calculation mechanisms with a simpler database lookup approach. Instead of continuously solving complex equations to determine consumption factors, the controller substitutes this with direct retrieval of pre-calculated consumption factor data based on detected machining conditions, simplifying the control system architecture.
3Measurement precision
If the controller selects tools based on accumulated consumption life considering changing machining conditions, then tool life management accuracy improves, but the calculation and selection process becomes more complex
Solution Approach 1:
The patent segments the tool life calculation process into discrete blocks of the machining program, calculating accumulated consumption life block by block. This segmentation allows the controller to manage complexity by handling calculations in small, manageable units rather than attempting to calculate the entire tool life consumption in one complex operation, while maintaining precise tracking of tool life usage.
Data Source
AI summary
A numerical controller determines a consumption factor representing the degree to which a tool included in a machine tool consumes the life in association with machining conditions, and calculates a tool life (accumulated consumption life) consumed before each block based on the determined consumption factor and a tool usage for each block. If a command of a block read from a machining program is a tool change command, a tool having a tool life not ending before the next tool change command is selected among tools based on the accumulated consumption life.