Cutting Tool Current Waveform Inspection Without Timing Signals
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Solution Overview
Problem
Existing cutting tool inspection techniques fail to automatically determine anomalies in different cutting tools during various processes without a timing signal from the machine tool, specifically during processes like finishing, as they do not implement a waveform extraction function.
Innovation Solution
A cutting tool inspection apparatus and method that infers a time range corresponding to a specific process by analyzing waveform data characteristics, allowing for the generation of training and inspection data even without a timing signal, using threshold levels and clipping processes to align and correct time positions within the inspection data.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If waveform data is analyzed without timing signals from the machine tool, then anomaly detection capability is improved, but data extraction accuracy deteriorates due to inability to identify specific process intervals
Solution Approach 1:
The patent introduces an intermediary process that uses waveform characteristics (current peaks, valleys, and patterns) as mediators to indirectly identify process intervals without direct timing signals. The system analyzes the motor current waveform to infer process boundaries, using the waveform itself as a mediator between the absence of timing signals and the need for accurate data extraction.
Solution Approach 2:
The patent replaces the mechanical/timing signal-based system with a waveform analysis-based system. Instead of relying on external timing signals from the machine tool controller, the system substitutes this with analysis of the motor current waveform characteristics to determine process intervals, eliminating the dependency on timing signals.
2Measurement precision
If timing signals are required for accurate data extraction, then data extraction accuracy is improved, but system complexity increases due to additional signal requirements
Solution Approach 1:
The system performs self-service by using its own acquired waveform data to identify process intervals and extract training data. Instead of requiring external timing signals from the machine tool, the inspection apparatus uses the characteristics of the motor current waveform it already captures to autonomously determine when to extract data for specific processes.
Solution Approach 2:
The waveform data serves multiple functions: it is used both for anomaly detection and for identifying process intervals. The same motor current waveform that contains anomaly information also contains temporal information about process boundaries, eliminating the need for separate timing signal systems.
3Adaptability or versatility
If waveform characteristics are used to infer process intervals, then adaptability to different machine tools is improved, but time synchronization accuracy deteriorates
Solution Approach 1:
The patent changes the parameter basis for interval identification from fixed timing signals to variable waveform characteristics. By using current peaks, valleys, and pattern recognition in the waveform data, the system adapts to different machine tools and processes without requiring precise time synchronization, as it relies on the inherent characteristics of each waveform rather than absolute timing.
Data Source
AI summary
The cutting tool inspection apparatus includes a data collection unit, a training data generation unit, and an inspection data generation unit. The data collection unit acquires waveform data of current for one batch supplied to a motor that drives a cutting tool of a machine tool. During generation of training data to be compared with inspection data of the cutting tool, the training data generation unit infers a time range corresponding to a specific process of the machine tool, based on characteristics of the waveform data, and clips waveform data of the time range as the training data. The inspection data generation unit clips, as the inspection data, waveform data at a time position identical to a time position of the time range inferred by the training data generation unit, from the waveform data acquired by the data collection unit during inspection of the cutting tool.