Lathe Cut-Off Tool Breakage Detection Without Machining Delay
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Solution Overview
Problem
Conventional non-mechanical-type breakage detecting means in lathes are ineffective for immediate detection of cut-off tool breakage after a top cut or at the start of continuous machining, and replacing them with mechanical-type detectors would elongate machining time.
Innovation Solution
A lathe equipped with a contact-type breakage detector having a retractable sensor that advances to hit the end of the bar material if it remains after cutting, allowing for accurate detection of cut-off tool breakage without elongating machining time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a mechanical-type breakage detector is used to detect cut-off tool breakage, then detection accuracy is improved, but machining time is elongated
Solution Approach 1:
The sensor is designed to be retractable rather than fixed, allowing it to dynamically advance to the working position only when needed for detection. This dynamic configuration enables the sensor to contact the bar material end for accurate breakage detection while retracting during normal machining operations, thus avoiding continuous interference with the machining process and preventing time elongation
Solution Approach 2:
The sensor advances to the working position in advance of the actual breakage detection moment. By positioning the sensor at the ready state before detection is needed, the system eliminates the time required for sensor positioning during the critical detection phase, enabling immediate and accurate breakage detection without adding to machining time
2Productivity
If a non-mechanical-type breakage detector is used, then machining time is reduced, but detection accuracy is insufficient for top cut and continuous machining start conditions
Solution Approach 1:
The retractable sensor acts as an intermediary between the non-mechanical control system and the physical bar material. It can contact the bar material end to detect breakage conditions that non-mechanical sensors cannot detect (such as when the back spindle does not hold the material), while still being controllable through the NC system, thus bridging the gap between rapid non-mechanical detection and accurate mechanical detection
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 lathe achieves improved accuracy in cut-off tool breakage detection without prolonging continuous machining time, ensuring reliable operation and minimizing the impact of tool breakage on subsequent operations.
Implementation Method 1
a contact-type breakage detector provided with a sensor retractably advancing to an advancing position where the sensor could hit the end of the bar material if it remains after the cut-off tool cuts off the bar material
Data Source
AI summary
A lathe includes a spindle, an opposite spindle, a tool post, a controller, and a contact-type breakage detector. The controller determines whether the cut-off tool is broken according to a control parameter for controlling at least one of the spindle and the opposite spindle at a first detection timing immediately after the cut-off tool cuts off the bar material while the opposite spindle holds the bar material held by the spindle. The controller determines whether the cut-off tool is broken according to a detection result by the contact-type breakage detector at a second detection timing different from the first detection timing.