Machine Tool Filter Lifetime Prediction Using Pressure Change
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing filter lifetime prediction methods for machine tools are cumbersome and prone to prediction errors due to the need for frequent parameter adjustments when workpiece shapes or dimensions change, and they do not accurately reflect the true filter lifetime.
Innovation Solution
A lifetime prediction device that includes a pressure acquisition unit, a time acquisition unit, and a calculation unit to predict the remaining filter lifetime by analyzing pressure changes over time, allowing for accurate predictions regardless of machining conditions or machine tool models.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If parameters such as machining conditions are set to values corresponding to the shape and dimensions of the workpiece, then prediction accuracy is improved, but operation complexity increases due to frequent parameter adjustments
Solution Approach 1:
The filter lifetime prediction device automatically acquires pressure values from pressure sensors and machining times from control units, then calculates and predicts filter lifetime without requiring operator intervention for parameter setting. The system serves itself by using readily available operational data to generate predictions, eliminating the need for manual parameter adjustments while maintaining high prediction accuracy
Solution Approach 2:
The system continuously monitors pressure values during filter operation and uses this feedback to calculate pressure changes over time. This real-time feedback mechanism allows the prediction device to dynamically update lifetime predictions based on actual operating conditions, achieving accurate predictions without manual parameter intervention
2Ease of operation
If parameters are not set to values corresponding to the workpiece characteristics, then operation simplicity is improved, but prediction error increases
Solution Approach 1:
The prediction device automatically obtains pressure values from pressure sensors and machining times from control units already present in the machine tool. By using self-service and existing system data, the invention achieves both operational simplicity and prediction accuracy without requiring manual parameter setting or external input
3Productivity
If filter replacement is delayed beyond predicted lifetime, then productivity is improved by avoiding premature replacement, but reliability decreases due to potential filter failure
Solution Approach 1:
The prediction device calculates and provides filter lifetime predictions in advance based on pressure change analysis. This preliminary information allows operators to plan filter replacement at the optimal time - neither too early nor too late - thereby maintaining both high productivity through avoided premature replacement and high reliability through timely replacement before failure occurs
Data Source
AI summary
Provided is a lifetime prediction device and a machine tool that enable simple prediction of the lifetime of a filter while suppressing a prediction error with respect to a true value. A lifetime prediction device (88) according to one embodiment is provided with: a pressure acquisition unit (90) that acquires in time series a pressure value of a liquid applied to a filter (52); a time acquisition unit (92) that acquires processing time of a designated process; a calculation unit (94) that calculates the amount of pressure change during the processing time; and a prediction unit (96) that predicts a lifetime period before an upper limit value of the pressure of the liquid applied to the filter (52) is reached, by using the pressure value, the processing time, and the pressure change amount at the time of completion of the designated process.