Electrospindle Sensor Data Bridge for Legacy CNC Machine Tools
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Solution Overview
Problem
Machine tools often lack suitable monitoring electronics to fully utilize the advanced features of new operating devices, such as electrospindles, which are equipped with sensors providing additional operational data that could enhance machining efficiency but are not effectively utilized due to outdated computer numerical control units.
Innovation Solution
An electrospindle with integrated sensors and an electronic control unit that collects and processes machine tool operating data, transmitting it to an external server for storage and analysis, allowing for the exploitation of this data without requiring updates to the machine tool's control unit, effectively transforming a 'low-end' machine tool into a 'high-end' one.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of information
If new operating devices with advanced sensors are installed on the machine tool, then the quantity and quality of operational data is improved, but the machine tool cannot effectively utilize this data due to outdated control electronics
Solution Approach 1:
A portable electronic device serves as an intermediary between the sensors on the operating device and the machine tool's control unit. This intermediary collects data from sensors, processes it, and transmits it to the control unit via wireless communication, enabling data utilization without requiring upgrades to the machine tool's control electronics.
Solution Approach 2:
The portable electronic device autonomously performs data collection, processing, and transmission functions. It independently manages the communication between sensors and the control system, eliminating the need for the machine tool's control unit to have advanced capabilities for handling sensor data.
2Adaptability or versatility
If the machine tool's computer numerical control unit is upgraded to handle advanced sensor data, then the adaptability and data processing capability is improved, but the cost of upgrading increases significantly
Solution Approach 1:
The portable electronic device acts as a cost-effective intermediary that bridges the gap between simple sensors and the existing control unit. Instead of upgrading the expensive control unit, the intermediary handles complex data processing functions at lower cost.
Solution Approach 2:
The portable electronic device provides an inexpensive alternative to permanent control unit upgrades. It can be easily replaced or updated without significant investment in the machine tool's core control system.
3Measurement precision
If additional sensors and monitoring electronics are added to the machine tool, then the measurement precision and operational monitoring is improved, but the device complexity and cost increase
Solution Approach 1:
The monitoring system is segmented into separate functional components: sensors remain on the operating device, data processing occurs on the portable electronic device, and only processed information is transmitted to the control unit. This segmentation reduces overall system complexity.
Solution Approach 2:
The complex data processing and communication electronics are extracted from the machine tool and placed on a separate portable device. This leaves the machine tool's control system simple while still enabling advanced monitoring capabilities.
Data Source
AI summary
An operating device for a machine tool, the operating device comprising at least one spindle or electrospindle, sensor means to measure at least one operating parameter of the operating device and an electronic control unit, which comprises a processing and control unit, data acquisition devices configured to acquire machine data concerning the operation of the machine tool, a memory to store measured values of the operating parameter of the operating device and the machine data, and a communication module, preferably wireless, configured to transmit the measured values and the machine data to a server, which is remotely accessible and comprises a database, and/or to a mobile communication device.