Gap Sensor Interval Switching for Accurate Long-Range NC Detection
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Solution Overview
Problem
Conventional numerical control devices face limitations in increasing the detectable distance of gap sizes due to limited storage capacity, leading to decreased detection accuracy when trying to widen measurement intervals for nonlinear gap sensors.
Innovation Solution
A numerical control device that includes a data storage unit for gap sensor output voltages, a correlation table generation unit, a displacement amount calculation unit, a gap control unit, and a measurement interval control unit, which generates and switches measurement intervals to create a correlation table for accurate gap size detection, allowing for increased detectable distance while maintaining high accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If measurement intervals are widened to increase detectable distance, then the detectable distance increases, but detection accuracy decreases
Solution Approach 1:
The patent applies dynamics by making the measurement interval adjustable rather than fixed. The control unit dynamically changes the measurement interval based on the detected gap size: using smaller intervals when the gap is small (for high accuracy) and larger intervals when the gap is large (for extended range). This resolves the contradiction by allowing the system to adapt the measurement interval to the current operating conditions, achieving both extended detectable distance and maintained detection accuracy.
Solution Approach 2:
The patent changes the parameter of measurement interval based on the gap size. By storing multiple measurement intervals and selecting appropriate intervals based on the current gap range, the system optimizes the balance between detectable distance and detection accuracy. This parameter change strategy allows the system to use fine measurement intervals for small gaps (ensuring accuracy) and coarse intervals for large gaps (extending range).
2Measurement precision
If the number of samples is increased to improve detection accuracy, then detection accuracy improves, but storage capacity is exceeded
Solution Approach 1:
The system dynamically adjusts the number of samples stored based on the gap size range. By using smaller measurement intervals only when necessary (for small gaps requiring high accuracy) and larger intervals for normal operation, the system reduces the total number of samples needed while maintaining accuracy where required. This dynamic sampling strategy resolves the contradiction between accuracy and storage capacity.
Solution Approach 2:
The patent applies local quality by using different measurement intervals for different gap size ranges. Instead of uniformly using small intervals throughout the entire range (which would consume excessive storage), the system uses fine intervals only in the critical small-gap region where high accuracy is needed, and coarser intervals elsewhere. This localized approach to measurement quality optimizes the balance between accuracy and storage usage.
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 solution enables the numerical control device to detect larger distances with high accuracy by dynamically switching measurement intervals based on the correlation table, ensuring precise gap size detection even with nonlinear gap sensor outputs.
Implementation Method 1
for example, in the case of a gap sensor of an electrostatic capacitance type or the like, the relationship between its output voltages and the gap size is not proportional
Data Source
AI summary
The present invention provides technology which makes it possible, in a numerical control device for detecting a gap size on the basis of a relationship between the gap size and a nonlinear gap sensor output voltage, to increase the distance that can be detected by the numerical control device while ensuring high detection accuracy of the gap size. This numerical control device 1 comprises: a measurement interval storage unit 12 which stores multiple measurement intervals of output voltage measured by a gap size measurement unit 21, and stores a switching position for switching measurement intervals; a measurement interval control unit 13 which, on the basis of the measurement intervals and the switching position stored in the measurement interval storage unit 12, switches, at the switching position, the measurement interval of the output voltage measured by the gap size measurement unit 21; and a correlation table generation unit 14 which generates a correlation table of the correlation between the output voltage and the gap size on the basis of output voltage that is measured by the gap size measurement unit 21, with the measurement interval of the output voltage being switched at the switching position by the measurement interval control unit 13, and that is stored in a data storage unit 11.