Multi-directional Line Sensor Tool Shape Measurement
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Solution Overview
Problem
Existing tool shape measuring apparatuses struggle to detect shape abnormalities in tools with multiple cutting edges, particularly when one edge is chipped, as the rotation of the tool masks any changes in the contour during measurement.
Innovation Solution
A tool shape measuring apparatus with a light projecting and receiving section, utilizing line sensors arranged perpendicularly and at right angles to the tool's rotational axis, allowing for precise contour detection by analyzing the output states of the sensors to identify changes in the cutting edge positions, and calculating runout widths to determine shape abnormalities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the tool is rotated during measurement to capture the general shape, then the overall tool shape can be measured, but detection of chipping on individual cutting edges becomes impossible because no contour change occurs
Solution Approach 1:
The light receiving face is segmented into multiple line sensors arranged in different directions, allowing detection of contour changes in specific orientations. This segmentation enables the system to detect chipping on individual cutting edges by analyzing light blockage patterns in different directions, resolving the contradiction between detecting local defects and measuring overall shape.
Solution Approach 2:
The patent transitions from conventional 2D area sensor measurement to a multi-dimensional approach using line sensors arranged in different directions on the light receiving face. By adding directional dimensionality to the measurement, the system can detect contour changes that would be invisible in standard rotation-based measurement, enabling chipping detection while maintaining overall shape measurement capability.
2Measurement precision
If multiple line sensors are arranged in different directions on the light receiving face, then contour detection accuracy is improved, but the device configuration becomes more complex
Solution Approach 1:
The multi-directional line sensor arrangement serves multiple functions simultaneously: it detects overall tool shape, identifies individual cutting edges, and detects chipping or abnormalities. This universal configuration eliminates the need for separate measurement systems for different measurement objectives, resolving the contradiction between enhanced precision and increased complexity.
3Measurement precision
If the light receiving section uses an area sensor to image the tool, then the general shape can be captured, but shape abnormalities in rotating tools are not detected due to lack of contour change
Solution Approach 1:
Instead of using an area sensor to capture the entire tool contour and hoping to detect abnormalities, the patent inverts the approach by using line sensors to detect light blockage patterns caused by cutting edges. This inversion transforms the measurement paradigm from direct contour imaging to indirect detection through light blockage analysis, enabling abnormality detection while preserving contour measurement capability.
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
Enables accurate detection of shape abnormalities in cutting edges without the need for complex image processing, reducing calculation load and increasing measurement speed, allowing for timely identification of chipping or wear.
Implementation Method 1
a light projecting section configured to emit an irradiation light to the tool; a light receiving section disposed opposite the light projecting section across the tool therebetween, the light receiving section being configured to receive the irradiation light through a lens
Implementation Method 2
the light receiving section being set at a position where a contour of the tool is imaged by the lens
Implementation Method 3
each line sensor having a plurality of sensor elements arranged in one direction; wherein the respective line sensor is disposed across a first area not reached by the irradiation light as being completely blocked by the tool, a second area disposed adjacent the first area and reached by the irradiation light with a portion thereof being blocked, and a third area disposed adjacent the first area and reached by the irradiation light not blocked at all
Data Source
Figure 1
Figure 2~3
Figure 4(a)~4(c)
AI summary
There is provided a tool shape measuring apparatus that allows detection of shape abnormality in a tool having a plurality of cutting edges with a simple configuration. A light receiving section 6 includes a light receiving face 9 perpendicular to an optical axis 6b of a light receiving lens 6a. In the light receiving face 9, there are disposed a plurality of line sensors 8 arranged in different directions from each other, each line sensor having a plurality of sensor elements arranged in one direction. The line sensor 8 is disposed across a first area not reached by the irradiation light L as being completely blocked by the tool 4, a second area disposed adjacent the first area and reached by the irradiation light L with a portion thereof being blocked, and a third area disposed adjacent the second area and reached by the irradiation light L not blocked at all. A calculation section 21 checks change occurring in output states of the line sensor 8 associated with rotation of the tool 4 and specifies a contour position of the tool 4 based on a center position in the second area when the number of the sensor elements included in the second area becomes minimal.