Feed Axis Monitoring by Surface-Normal Deviation Thresholds
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Solution Overview
Problem
Existing machine tools struggle to accurately determine abnormalities in feed axes that affect machined surface properties due to varying thresholds for different machining operations, leading to unnecessary replacements of parts that are still usable.
Innovation Solution
A feed axis monitoring device and method that calculates position deviations and converts them into components perpendicular to the machined surface, using threshold values based on the main spindle's operating state to determine abnormalities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a fixed threshold value is used to detect feed axis abnormalities, then the detection method is simple, but it leads to unnecessary part replacements in parts machining while missing critical abnormalities in die machining
Solution Approach 1:
The patent applies dynamics by making the threshold value variable rather than fixed. The threshold is dynamically adjusted based on the machining type (parts machining vs. die machining) and the operating state of the main spindle. This allows the system to adapt to different machining conditions, preventing unnecessary replacements in parts machining while ensuring critical abnormalities are detected in die machining.
Solution Approach 2:
The patent changes the parameter of the threshold value based on machining conditions. By modifying the threshold parameter according to the type of machining being performed and the spindle's operating state, the system achieves both simplicity and accuracy in abnormality detection across different machining scenarios.
2Reliability
If early part replacement is performed to ensure machined surface quality, then production stability is improved, but production efficiency decreases due to unnecessary replacements
Solution Approach 1:
The system dynamically adjusts the abnormality threshold based on machining conditions, allowing later replacement timing for parts machining where surface quality is less sensitive, while maintaining earlier replacement for die machining where surface quality is critical. This dynamic approach optimizes both production stability and efficiency.
Solution Approach 2:
The patent applies local quality by recognizing that different machining operations have different requirements for machined surface quality. Parts machining tolerates higher position deviations, while die machining requires stricter control. The system applies different threshold criteria locally to each machining type, avoiding unnecessary replacements while ensuring quality where needed.
3Ease of operation
If position deviation is monitored without considering machining direction, then the monitoring method is simple, but it cannot accurately assess impact on machined surface property
Solution Approach 1:
The patent adds a directional dimension to position deviation monitoring. Instead of simply measuring the magnitude of position deviation, the system projects the deviation onto the direction perpendicular to the machined surface. This dimensional transformation allows accurate assessment of surface quality impact while maintaining relatively simple monitoring implementation.
Data Source
AI summary
A feed axis monitoring device includes a position deviation calculating unit, a machined surface perpendicular direction calculating unit, a position deviation component converting unit, a threshold value calculating unit, and an abnormality determining unit. The position deviation calculating unit calculates a position deviation of the feed axis. The machined surface perpendicular direction calculating unit calculates a direction perpendicular to a machined surface at a time of a position deviation calculation. The position deviation component converting unit converts a position deviation of the feed axis into a component in the perpendicular direction. The threshold value calculating unit calculates a threshold value based on a preset relation between an operating state of the main spindle and the threshold value. The abnormality determining unit determines that the feed axis has an abnormality when the position deviation exceeds the threshold value.