Cutting Tool AD Sampling Control for Angle Pitch Accuracy
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Solution Overview
Problem
Existing systems that perform sampling on analog signals from sensors attached to cutting tools struggle to efficiently generate digital signals, particularly in determining optimal sampling frequencies and process periods to ensure accurate data acquisition without excessive computational resources.
Innovation Solution
A processing system that includes a cutting tool, a sensor, an AD converter, and a processing unit. The processing unit determines the process period and sampling frequency based on the rotation rate of the cutting tool, upper-limit periods, and upper-limit pitches, ensuring that the set value of the angle pitch is equal to or less than the upper-limit pitch within a specified time period, allowing for efficient digital signal generation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If sampling frequency is increased to improve data accuracy, then measurement precision is improved, but use of energy and computational resources increases
Solution Approach 1:
The patent implements periodic sampling synchronized with the rotation period of the cutting tool. The AD converter samples analog signals at specific intervals corresponding to rotational phases, rather than continuously or at fixed high frequencies. This periodic action captures essential data at critical moments while reducing overall sampling count, thereby maintaining measurement precision for rotational analysis while significantly lowering computational resource requirements.
Solution Approach 2:
The patent dynamically adjusts sampling parameters based on rotation speed and process requirements. The sampling frequency and process period are calculated as functions of the upper-limit period and upper-limit pitch parameters, allowing the system to adapt sampling intensity to actual operational conditions. This parameter optimization ensures sufficient data accuracy for the given rotational characteristics while minimizing unnecessary sampling operations that would consume computational resources.
2Use of energy by moving object
If sampling frequency is decreased to reduce computational demands, then use of energy is reduced, but measurement precision deteriorates
Solution Approach 1:
The system employs periodic sampling synchronized to the rotational period, capturing data at phase-specific intervals rather than uniformly. This ensures that critical measurement points corresponding to specific rotational positions are sampled with sufficient frequency, maintaining measurement precision for rotational analysis even when overall sampling rate is reduced to conserve computational resources.
Solution Approach 2:
The patent performs preliminary calculation of optimal sampling parameters based on upper-limit period and upper-limit pitch before actual data acquisition. By pre-determining the process period and sampling frequency that satisfy the angle pitch constraint, the system ensures measurement precision is maintained while avoiding excessive sampling. This preliminary optimization prevents both over-sampling (wasting resources) and under-sampling (losing precision).
3Productivity
If process period is shortened to improve productivity, then productivity is improved, but measurement precision may deteriorate due to reduced sampling points
Solution Approach 1:
The system uses periodic sampling synchronized with rotation, where the process period is set as a multiple of the rotational period. This ensures that even within shortened process periods, sufficient phase-specific sampling points are captured to maintain measurement precision. The periodic structure guarantees that critical rotational phases are sampled appropriately regardless of overall process duration.
Solution Approach 2:
The patent calculates process period and sampling frequency as coordinated parameters based on upper-limit period and upper-limit pitch. When productivity requirements demand shorter process periods, the system adjusts sampling frequency proportionally to maintain the angle pitch constraint, ensuring that measurement precision is preserved even as processing speed increases.
4Measurement precision
If angle pitch is reduced to improve measurement precision, then measurement precision is improved, but device complexity increases due to more sampling points
Solution Approach 1:
The system implements periodic sampling at phase-specific intervals rather than continuous sampling. By sampling only at predetermined rotational phases corresponding to the upper-limit pitch constraint, the system achieves required angle pitch accuracy without generating excessive data points. This periodic approach reduces the number of sampling operations and data processing requirements compared to continuous high-resolution sampling.
Solution Approach 2:
The patent pre-calculates optimal sampling parameters including process period and sampling frequency based on upper-limit pitch requirements. This preliminary determination of sampling points avoids the need for complex real-time adjustments and reduces the overall number of sampling operations required to achieve the desired angle pitch accuracy, thereby simplifying the sampling system while maintaining measurement precision.
Data Source
AI summary
A processing system includes a cutting tool, a sensor attached to the cutting tool, an analog-to-digital (AD) converter configured to perform sampling on an analog signal output from the sensor to generate a digital signal, and a processing unit. The processing unit is configured to, based on a rotation rate [rpm] of a rotor; an upper-limit period that is an upper-limit value of a process period; and an upper-limit pitch that is an upper-limit value of an angle pitch [degree], determine the process period and a sampling frequency with which the AD converter performs sampling such that a set value of the angle pitch is equal to the upper-limit pitch or less in a time period taken by the rotor to rotate N times with the process period that is equal to the upper-limit period or shorter.