Elastic Piezo Sensor Mounting in Cutting Tools for Force Sensing
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Solution Overview
Problem
Existing cutting tools equipped with piezo sensors are expensive, complex, and lack reliability and accuracy due to the use of rigid sensors that wear out quickly and require high geometric tolerances, leading to potential tool failure and increased maintenance costs.
Innovation Solution
A cutting tool design featuring an elastically deformable piezo sensor with a pre-stressed initial state, integrated into a sensor retaining structure that deforms under cutting forces, allowing for the use of a generic and cost-effective sensor, while maintaining accuracy and reliability by registering stress through a plurality of stressed measuring states.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If rigid piezo sensors are used in cutting tools, then measurement capability is provided, but the tool becomes expensive and complex
Solution Approach 1:
The patent changes the mechanical parameters of the sensor from rigid to elastically deformable, allowing the sensor to flex under cutting forces while maintaining measurement capability. This elasticity enables the use of simpler, less expensive sensor designs that can withstand the dynamic loading conditions of cutting operations.
Solution Approach 2:
The sensor retaining structure incorporates dynamic elements that allow controlled movement and deformation during cutting operations. The elastically deformable sensor can dynamically respond to varying cutting forces without requiring complex rigid mounting structures, reducing overall device complexity.
2Measurement precision
If rigid piezo sensors are used in cutting tools, then measurement capability is provided, but reliability decreases due to quick wear out
Solution Approach 1:
Changing the sensor from rigid to elastically deformable allows it to absorb mechanical shocks and stresses during cutting operations. The elastic properties enable the sensor to return to its original shape after deformation, preventing permanent damage and extending service life.
Solution Approach 2:
The elastically deformable sensor structure acts as a cushioning element that absorbs peak loads and shock forces before they can damage the sensing elements. This pre-built-in elastic compliance protects the sensor from wear and failure during normal cutting operations.
3Manufacturing precision
If high geometric tolerances are applied to the sensor, then positioning accuracy is improved, but manufacturing cost increases
Solution Approach 1:
The elastically deformable sensor can accommodate variations in positioning through its inherent flexibility. Instead of requiring precise rigid alignment, the elastic structure naturally adjusts to fit within the retaining structure, significantly easing manufacturing and installation requirements.
Solution Approach 2:
The elastic sensor structure functions similarly to a flexible element that can deform to accommodate manufacturing tolerances. This flexibility eliminates the need for high-precision machining and alignment procedures, reducing manufacturing costs and complexity.
4Adaptability or versatility
If the piezo sensor is made specifically for various tool and insert size combinations, then adaptability is improved, but device complexity increases
Solution Approach 1:
The elastically deformable sensor design creates a universal mounting solution that can accommodate various tool and insert sizes. The elastic structure naturally adapts to different geometries without requiring custom-designed sensors for each application, enabling a single sensor type to serve multiple purposes.
Solution Approach 2:
The dynamic elastic properties of the sensor allow it to adapt its deformation characteristics based on the specific tool and insert configuration. This dynamic adaptability provides versatility across different applications without requiring multiple specialized sensor designs.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides a resilient, reliable, and cost-effective cutting tool with improved accuracy and reduced maintenance needs, as the elastically deformable piezo sensor can detect cutting forces without compromising tool performance and extends the tool's lifespan by distributing mechanical stress effectively.
Implementation Method 1
piezo sensors. This type of sensor is based on the piezo electric effect, meaning that an electric charge accumulates in certain solid materials in response to an applied mechanical stress.
Implementation Method 2
The piezo sensor is an elastically deformable piezo sensor, which has a central longitudinal axis and a direction of sensitivity perpendicular to the central longitudinal axis.
Data Source
Figure 1a~1d
Figure 2a~2b
Figure 3a~3c
AI summary
A cutting tool (1) comprising a tool body (2) comprising at least one seat (3) for receiving a cartridge (4) or a cutting insert (5), wherein the seat (3) comprises at least one support surface (6). The cutting tool body (2) comprises a sensor retaining structure (7) adjoining the support surface (7) and a piezo sensor (8) arranged in the sensor retaining structure (7). The cutting tool (1) comprises clamping means (9) for securing the cartridge (4) or cutting insert (5), and the piezo sensor (8) is an elastically deformable piezo sensor (8), which has a central longitudinal axis (24) and a direction of sensitivity perpendicular to the central longitudinal axis (24). The piezo sensor (8) comprises a measuring section (10), along which the central longitudinal axis (24) is substantially parallel to the support surface (6). The piezo sensor (8) is elastically deformed in the sensor retaining structure (7) to a pre-stressed initial state (19) and deformable to a plurality of further stressed measuring states (21).