Electronic Gauge Block Setup for Machine Tool Positioning
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Solution Overview
Problem
Current machine tool setup processes lack precision and efficiency, particularly in accurately positioning workpieces during manufacturing, due to environmental factors and debris-related seating failures, which can lead to inaccuracies and damage to the workpiece.
Innovation Solution
The implementation of X-axis, Y-axis, and Z-axis electronic gauge block assemblies with environmental sensors and a wireless interface to establish refined coordinate systems, assisting machinists with precise setup and real-time adjustments on a machine tool table, using a display for improved accuracy and minimizing seating failures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional manual setup methods are used with standard digital readout values, then the setup process is simpler, but positioning accuracy deteriorates due to environmental factors and debris
Solution Approach 1:
The patent replaces manual mechanical measurement methods with an automated probe system that uses electronic sensors and computer processing to determine precise coordinates. The probe automatically measures the workpiece and vise positions, substituting human manual operations with automated mechanical-electronic systems to achieve higher precision without environmental interference
Solution Approach 2:
The patent introduces electronic gauge blocks as intermediary reference objects between the workpiece and the measurement system. These gauge blocks serve as mediators that establish known reference positions, allowing the probe system to calculate precise coordinates by measuring relative positions to these stable intermediary references rather than directly to the workpiece
2Manufacturing precision
If environmental factors are not compensated for, then the setup process is faster, but manufacturing precision deteriorates due to temperature and humidity variations
Solution Approach 1:
The patent implements environmental sensors that continuously monitor temperature and humidity conditions and feed this data back to the computer system. The system uses this feedback to dynamically compensate for environmental effects on measurements, adjusting calculations in real-time to maintain precision without requiring manual environmental corrections
Solution Approach 2:
The patent changes the measurement parameters by incorporating environmental condition data into the coordinate calculation process. Instead of using fixed reference values, the system adjusts measurement parameters based on real-time environmental readings, transforming static measurement procedures into dynamic adaptive measurements that compensate for environmental variations
3Reliability
If debris is present on reference surfaces, then the setup process continues without interruption, but seating failure occurs leading to workpiece damage
Solution Approach 1:
The patent performs preliminary probing measurements before final workpiece clamping to detect potential seating failures. The probe system measures the workpiece position and compares it against expected coordinates derived from gauge block references, identifying seating issues before they cause damage to the workpiece during machining operations
Data Source
AI summary
An apparatus to assist a machinist in the setup of a remote computer controlled machine tool table has an X-axis electronic gauge block assembly, a Y-axis electronic gauge block assembly, and a Z-axis electronic gauge block assembly each positioned on the machine tool table, to respectively collect X-axis probe position values, Y-axis probe position values, and Z-axis probe position values. Environmental sensors collect environmental values. An electronics processing system establishes a raw X-axis probe position, a raw Y-axis probe position, and a raw Z-axis probe position. A wireless interface transmits the environmental values, the raw X-axis probe position value, the raw Y-axis probe position value, and the raw Z-axis probe position value to the remote computer and receives from the remote computer refined probe position values to assist the machinist in the setup of the machine tool table.