Feed Axis Resonance Mapping for Fault Localization
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Solution Overview
Problem
Conventional failure diagnostic methods for feed axis mechanisms in machine tools, such as those using resonance frequency analysis, struggle to accurately identify the specific cause of failures, as changes in resonance frequency can be influenced by various components like ball screws and couplings, making it difficult to pinpoint the exact abnormal portion.
Innovation Solution
An abnormality diagnostic device that measures resonance frequencies at multiple stroke positions and uses a diagnosis unit to identify abnormal portions by analyzing changes relative to standard values, employing thresholds and mathematical approximations to differentiate between coupling, ball screw, and nut or rolling body issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If resonance frequency analysis is used to diagnose feed axis mechanism failures, then the detection capability is improved, but the ability to identify specific abnormal portions deteriorates
Solution Approach 1:
The patent divides the feed axis mechanism into multiple segments (coupling, ball screw, nut, rolling body) and measures resonance frequencies at multiple stroke positions. By segmenting the diagnosis process into position-specific measurements, the system can identify which specific component is abnormal based on the pattern of resonance frequency changes across different positions, thus resolving the contradiction between detecting failures and identifying specific abnormal portions.
Solution Approach 2:
The patent adds the dimension of stroke position to the resonance frequency measurement. Instead of measuring resonance frequency at a single point, the system measures at multiple stroke positions along the feed axis. This dimensional expansion creates a resonance frequency map that enables identification of specific abnormal portions by analyzing how resonance frequencies vary across the stroke range.
2Measurement precision
If multiple resonance frequency measurements at different stroke positions are performed, then the abnormal portion identification accuracy is improved, but the diagnostic complexity increases
Solution Approach 1:
The patent implements a feedback mechanism where resonance frequency measurements at multiple stroke positions are fed back to a diagnostic system that compares actual measurements with predetermined reference values. The system automatically identifies abnormal portions by detecting deviations from reference patterns, reducing diagnostic complexity through automated comparison and decision-making algorithms.
Solution Approach 2:
The patent stores predetermined reference resonance frequency values and abnormality determination thresholds in advance. By preparing reference data and decision criteria beforehand, the system simplifies the actual diagnostic process, as it only needs to compare current measurements against pre-established standards rather than performing complex real-time analysis.
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 device can promptly detect abnormalities and accurately identify the cause, distinguishing between coupling and ball screw issues, enabling precise maintenance and reducing unplanned losses in machine tools.
Implementation Method 1
The resonance frequency measuring unit measures a resonance frequency at a plurality of stroke positions within a stroke range of the feed axis mechanism
Data Source
AI summary
An abnormality diagnostic device for a feed axis mechanism diagnoses an abnormality occurrence and an abnormal portion of the feed axis mechanism. The feed axis mechanism transmits a rotation of a motor to a ball screw coupled by a coupling to rotate the ball screw. The abnormality diagnostic device includes a resonance frequency measuring unit and a diagnosis unit. The resonance frequency measuring unit measures a resonance frequency at a plurality of stroke positions within a stroke range of the feed axis mechanism. The diagnosis unit identifies the abnormal portion based on a relationship between the stroke positions and change amounts relative to a standard value of the measured respective resonance frequencies.