Cutter Edge Life Estimation Using Encoder-Based Contact Detection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing machining technologies are unable to accurately determine the contact state of a tool with a material, leading to inaccurate estimation of tool abrasion and life expectancy.
Innovation Solution
A machining apparatus equipped with servomotors and encoders to control the conveyance of materials and movement of cutting tools, allowing for precise calculation of positional relationships and estimation of tool life based on load measurements during contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the contact state is determined based on the amount of change in load per unit time, then the determination process is simple, but the accuracy of contact state determination deteriorates
Solution Approach 1:
The patent replaces the mechanical/load-based contact detection method with a positional relationship-based method. Instead of relying on load change measurements, the system uses encoder data to calculate the positional relationship between the tool and material, thereby substituting a less accurate mechanical sensing approach with a more precise positional calculation approach.
Solution Approach 2:
The patent introduces positional relationship information as an intermediary parameter between the tool-material interaction and contact state determination. By calculating the positional relationship based on encoder readings and comparing it with predetermined ranges, the system achieves accurate contact state determination without directly measuring load changes.
2Device complexity
If the contact state determination is inaccurate, then the estimation process remains simple, but the tool life estimation accuracy deteriorates
Solution Approach 1:
The patent substitutes the inaccurate load-based contact state determination with a positional relationship-based determination method. By using encoder data to calculate whether the tool is within a predetermined positional range relative to the material, the system achieves accurate contact state identification, which then enables accurate tool life estimation through load integration during confirmed contact periods.
3Measurement precision
If positional relationship calculation is implemented for accurate contact state determination, then contact state determination accuracy improves, but the device complexity increases
Solution Approach 1:
The patent makes the existing encoder components serve a dual function: their primary function for servomotor control and an additional function for calculating positional relationship information. By reusing the encoder data already present in the control system for both control purposes and contact state determination, the patent avoids adding separate sensing devices while achieving accurate contact detection.
Solution Approach 2:
The control system uses its own existing resources (encoder data and calculation capabilities) to determine contact state, rather than relying on external or additional specialized components. The system serves itself by leveraging its positional information infrastructure to solve the contact detection problem.
Data Source
AI summary
A machining apparatus includes encoders that detect first rotational positions of motors that respectively drive an unwind shaft and a take-up shaft for conveying a material, an encoder that detects a second rotational position of a motor that drives a cutter edge for cutting the material, and a controller that controls the motor based on the first rotational position and controls the motor based on the second rotational position to coordinately control conveyance of the material and movement of the cutter edge. The controller calculates positional relationship information representing a positional relationship between the material and the cutter edge based on the second rotational position, determines whether the cutter edge is in contact with the material based on the positional relationship information, and estimates a life of the cutter edge based on a load on the motor when the tool is in a contact state.