Feed Axis Usage Mapping for Ball Screw Life Prediction
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Solution Overview
Problem
Existing machine tools face challenges in accurately predicting the life of feed axis components like ball screws and bearings due to varying actual operating states, leading to increased lost-motion and potential malfunctions, especially in specific processing tasks where certain parts are overused, making it difficult to determine the optimal replacement timing.
Innovation Solution
An operating state display device and method that divides the feed axis operation range into sections, counts passage numbers, calculates use frequencies for different operation types, and displays these frequencies on a monitor, along with threshold calculations based on the length of life and cutting feed type ratios, to accurately monitor and understand the operating state of the feed axis.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the feed axis is used intensively in specific processing positions, then productivity is improved, but the ball screw and bearing are abraded faster causing premature failure
Solution Approach 1:
The operating range of the feed axis is divided into multiple sections, and the usage frequency is calculated for each section separately. This segmentation allows identification of which specific sections are being overused, enabling targeted usage adjustment rather than blanket reduction across the entire axis.
Solution Approach 2:
The system continuously monitors and calculates the usage frequency of each section, providing feedback to the operator through display. This feedback mechanism enables the operator to understand the actual wear pattern and adjust the processing plan to distribute usage more evenly across different sections.
2Ease of manufacture
If component replacement is performed based on theoretical life calculation, then maintenance planning is simplified, but actual operating state variations cause inaccurate life prediction
Solution Approach 1:
The patent replaces the purely theoretical mechanical life calculation system with an electronic monitoring and calculation system. The control device electronically tracks actual usage patterns, counts passage numbers, and calculates usage frequencies, substituting theoretical estimation with actual measured data.
Solution Approach 2:
The control device acts as an intermediary between the mechanical components and the maintenance decision-making process. It collects raw usage data, processes it through usage frequency calculations, and presents processed information that bridges the gap between complex actual operating conditions and simple maintenance scheduling.
3Reliability
If usage position adjustment is implemented to distribute wear, then component life is extended, but operational complexity and setup time increase
Solution Approach 1:
The system enables self-service by automatically monitoring and calculating usage frequencies without requiring external intervention. The control device autonomously tracks passage numbers, divides sections, and computes usage frequencies, reducing the need for complex manual tracking and management procedures.
Data Source
AI summary
An operating state display device displays an operating state of a feed axis in a machine tool including the feed axis. The feed axis linearly moves a moving body via a ball screw with a servomotor. The operating state display device includes a passage number count unit, a use frequency calculation unit, and a display unit. The passage number count unit preliminarily divides an operating range of an axis operation of the feed axis into a predetermined number of sections and counts passage numbers of the moving body in the respective sections. The use frequency calculation unit calculates frequencies of use in respective classified types of the axis operation in each of the sections based on the counted passage numbers. The display unit displays the calculated frequencies of use in the respective classified types on a monitor in a predetermined aspect.