Machine Control Device for Collision Detection via Electrical Field
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Solution Overview
Problem
Current systems for preventing collisions between machine elements and objects in machines, such as machine tools and robots, are ineffective in reducing damage and downtime due to late reaction and limited collision detection capabilities, particularly failing to account for workpiece and tool geometries accurately.
Innovation Solution
A method involving a control device with a program memory that implements targeted reactions by identifying contacts through displacement modes, force limits, and detection currents, allowing immediate stopping of machine axles to prevent further damage, and utilizing electrical insulation and voltage detection for safe contact identification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If mechanically operating systems with sensors are used for collision detection, then contact can be detected, but the reaction is delayed until force has built up in the mechanical structure, resulting in reduced damage only after collision has occurred
Solution Approach 1:
The patent replaces mechanical force-based detection systems with an electrical field-based detection system. Electrical sensors detect contact between machine elements and objects by measuring changes in electrical field distribution or contact current, enabling immediate detection without waiting for mechanical force to build up in structural components.
Solution Approach 2:
The system performs preliminary detection by continuously monitoring electrical parameters before a collision can cause significant damage. The electrical field is established in advance, and any contact disrupts this field immediately, triggering a reaction before mechanical forces can propagate through the structure.
2Reliability
If drive torque evaluation is used for collision identification, then collisions can be detected, but the response is late since collision is only identified if high drive force has already been built up
Solution Approach 1:
The patent substitutes mechanical drive torque evaluation with electrical parameter monitoring. Electrical sensors detect contact through changes in electrical conductivity, current flow, or field distribution, providing immediate detection without the delay inherent in mechanical force transmission and measurement.
Solution Approach 2:
The electrical field acts as an intermediary between the machine element and the detection system. Instead of directly measuring mechanical drive torque, the system uses electrical field changes as an intermediate indicator of contact, enabling faster and more sensitive detection.
3Reliability
If protection zones are monitored around clamping jaws and tailstock, then safety can be improved, but only simple geometries can be defined and the workpiece is generally not taken into consideration
Solution Approach 1:
The patent changes the detection parameter from geometric boundary monitoring to electrical field distribution monitoring. This allows complex workpiece geometries to be accommodated naturally, as the electrical field adapts to the actual spatial configuration of machine elements and objects, eliminating the need to pre-define protection zones for simple geometries only.
Solution Approach 2:
The electrical field detection system automatically adapts to the actual workpiece geometry and machine element configuration without requiring pre-programmed protection zones. The system self-adjusts based on the real-time electrical parameters, making it inherently versatile for complex geometries and dynamic workpiece variations.
4Reliability
If simulation functions with assumed tool and workpiece dimensions are used, then collisions can be identified, but loading with incorrect workpiece and incorrect tools cannot be identified, and errors when setting up a program cannot be identified
Solution Approach 1:
The electrical detection system automatically detects the actual dimensions and configuration of tools and workpieces during operation, eliminating reliance on assumed or programmed dimensions. The system self-calibrates by measuring actual electrical parameters, enabling detection of incorrect loading and setup errors without requiring precise pre-programming.
Solution Approach 2:
The system provides continuous feedback through electrical parameter monitoring, comparing actual conditions against expected ranges. This real-time feedback mechanism identifies deviations caused by incorrect workpiece loading, tool mismatches, or setup errors, enabling immediate correction without relying on simulation accuracy.
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
This approach enables early detection and prevention of collisions, reducing damage and downtime by allowing immediate stopping of machine axles during contact, even in rapid displacement modes, and simplifies collision identification through feedrate, cutting force, and drive current comparisons, ensuring accurate and efficient operation.
Implementation Method 1
If, as is often conventional practice, the drive torque of a drive of a machine axle to be displaced is evaluated
Implementation Method 2
the machine element and the object, and an electrical voltage is applied between the machine element and the object, the contact between the machine element and the object being identified by a detection current produced in the event of a contact being detected
Implementation Method 3
the machine element is arranged electrically insulated from the object
Data Source
AI summary
The invention relates to a method for the targeted reaction in the event of contact between an element (4, 6) pertaining to a machine and an object (5, 7), and a corresponding control device (14). Upon identification of contact between the machine element (4, 6) and the object (5, 7), if the machine axle is shifted into rapid displacement mode in an automated manner during the contact by means of a control device (14), further displacement of the machine axle (3, 41, 42, 43) is stopped by the drive (42, 43) of the machine (3, 41, 42, 43) being immediately cut off. Upon identification of contact, if the machine axle is shifted into slow displacement mode in an automated manner during the contact by means of a control device (14), collision detection is carried out, further displacement of the machine axle (3, 41, 42, 43) being stopped if a collision is detected. The invention thus enables the effects of a collision of an element (4, 6) pertaining to a machine with an object (5, 7) to be maintained as low as possible.