Lathe Tooling Calibration via Sensor Measurement

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Solution Overview

Problem

The calibration process for metalworking lathes is time-consuming, labor-intensive, and prone to errors, requiring multiple tools and precise measurements, which decreases productivity and increases the need for frequent recalibration due to wear and tear.

Innovation Solution

A system that uses sensors to measure and store tool dimensions and lathe parameters, allowing for automated calibration and eliminating the need for manual adjustment of movement parameters, enabling tools to be calibrated automatically for subsequent jobs with minimal operator intervention.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If manual calibration process is used to measure tool dimensions and lathe parameters, then measurement precision can be achieved, but the time and labor required increases significantly

Engineering Contradiction:

Improvetool dimension measurement precisionVSAvoidcalibration time

Core Design Contradiction:

Measurement precisionVSLoss of time

Solution Approach 1:

The patent replaces manual mechanical measurement processes with an automated sensor-based measurement system. Sensors automatically measure tool dimensions and lathe parameters, eliminating the need for operators to manually measure and record these values, thereby reducing calibration time while maintaining measurement precision.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The calibration system performs self-calibration by automatically measuring tool dimensions and lathe parameters without requiring continuous human intervention. The system stores measurement data and uses it to automatically adjust movement parameters, enabling the lathe to calibrate itself for subsequent jobs.

Inventive Principle:

Principle #25Self-service

2Reliability

If manual calibration process is used with multiple tools, then comprehensive calibration can be achieved, but labor intensity and error probability increase

Engineering Contradiction:

Improvecalibration accuracyVSAvoidcalibration operation complexity

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The patent replaces manual calibration operations with an automated sensor-based system that measures tool dimensions and lathe parameters. This substitution eliminates the complexity of manual measurement and recording processes while maintaining comprehensive calibration coverage across multiple tools.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system creates a digital record (copy) of tool dimensions and lathe parameters through automated sensing. These stored measurement data serve as reference copies that can be reused for subsequent calibration tasks, eliminating the need to repeat manual measurement processes for each new job.

Inventive Principle:

Principle #26Copying

3Manufacturing precision

If frequent recalibration is performed to account for wear and tear, then manufacturing precision is maintained, but productivity decreases

Engineering Contradiction:

Improvecomponent shaping precisionVSAvoidcomponent production rate

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The system performs preliminary calibration by automatically measuring and storing tool dimensions and lathe parameters before production begins. This preliminary calibration accounts for wear and tear effects in advance, allowing the lathe to maintain manufacturing precision throughout production without requiring frequent interruptions for recalibration.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The lathe system performs self-calibration using stored measurement data to automatically adjust movement parameters. This self-service capability allows the system to maintain manufacturing precision while minimizing interruptions to production flow, thereby preserving productivity.

Inventive Principle:

Principle #25Self-service

4Productivity

If automated sensor-based calibration system is implemented, then calibration time and labor are reduced, but device complexity increases

Engineering Contradiction:

Improvecalibration efficiencyVSAvoidcalibration system complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The sensor-based calibration system is designed to be universal, capable of measuring multiple tool dimensions and various lathe parameters with a single integrated system. This multi-functionality reduces the need for separate specialized measurement devices, thereby managing device complexity while maintaining high calibration efficiency.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS10675689B2Metal lathe and tooling calibration

Publication Date: 2020.06.09 ALLYN THOMAS

AI summary

Systems and methods for lathe and tooling calibration are disclosed. A sensor is utilized to measure dimensions and operational parameters of one or more components of a lathe, such as a turret, tool stations, and/or a spindle. Tool measurements are received and analyzed along with the measurements from the sensor. The dimensions and operational parameters may be utilized to calibrate movement parameters of one or more components of the lathe. Once calibrated, the lathe may be utilized to tool one or more objects.