Instrumented Cutting Tool Shaft for Wireless Strain Sensing
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Solution Overview
Problem
Existing cutting tools lack the capability to obtain detailed and accurate data during machining, limiting the understanding of their state and performance.
Innovation Solution
A cutting tool design featuring a shaft with a sensor device that includes a sensor module with strategically arranged strain and acceleration sensors on an octagonal-shaped region, allowing for simultaneous detection of strain and acceleration, and a wireless communication system for data transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a sensor device is added to the cutting tool to detect physical quantities during machining, then measurement precision and data accuracy are improved, but device complexity increases
Solution Approach 1:
The patent combines multiple sensors (strain sensors and acceleration sensors) into a single integrated sensor device that is mounted on the cutting tool shaft. This merging approach allows simultaneous detection of multiple physical quantities (strain in two directions and acceleration) while reducing overall system complexity compared to using separate sensor systems.
Solution Approach 2:
The sensor device is designed with multi-functionality by incorporating both strain sensors for detecting radial strain in two perpendicular directions and acceleration sensors for detecting vibration. This universal sensor device can monitor multiple aspects of cutting tool performance simultaneously, improving measurement precision without requiring multiple separate devices.
2Loss of information
If multiple sensors are arranged on the shaft to detect strain and acceleration simultaneously, then the quantity of information obtained is improved, but device complexity increases
Solution Approach 1:
The sensor device is segmented into distinct functional components: strain sensors arranged at specific positions on the shaft for detecting radial strain in two perpendicular directions, and acceleration sensors for detecting vibration. This segmentation allows each sensor type to be optimally positioned and configured while maintaining an organized overall structure that minimizes complexity.
Solution Approach 2:
The patent utilizes spatial arrangement in three-dimensional space by positioning strain sensors and acceleration sensors at different locations and orientations on the shaft. The strain sensors are arranged to detect strain in two perpendicular radial directions, and acceleration sensors are positioned to detect vibration, creating a comprehensive multi-dimensional monitoring system that maximizes information capture.
3Ease of operation
If a wireless communication unit is added to transmit sensor data, then ease of operation is improved, but device complexity increases
Solution Approach 1:
The patent replaces mechanical data transmission methods with a wireless communication unit that transmits sensor data and signals wirelessly. This substitution eliminates the need for physical connections and manual data retrieval, significantly improving ease of operation by allowing remote monitoring and real-time data access without interfering with the machining process.
Data Source
AI summary
A cutting tool includes a shaft, and a sensor device disposed in such a manner as to surround a portion of the shaft. The sensor device includes a sensor module including first sensors, a substrate connected to the first sensors, and a wireless communication unit connected to the substrate and configured to transmit a signal including information detected by the first sensors to outside and a housing accommodating the sensor module. A region of the shaft surrounded by the sensor device includes a first region having a shape of a 4n-sided polygon when viewed from a direction in which the rotation axis extends. The plurality of first sensors are arranged on at least two of outer peripheral surfaces of the first region, perpendicular lines of the outer peripheral surfaces passing through the rotation axis and intersecting at 90 degrees.