Machine Tool Sub-Panel Control for Abnormality Avoidance
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Solution Overview
Problem
Existing machine tools face issues where operators cannot quickly address abnormalities such as abnormal sounds or vibrations at the tool changer, leading to potential damage to workpieces due to delayed intervention and unexpected power-offs, especially in vertical machining centers.
Innovation Solution
A machine tool with a sub-operation panel featuring an abnormality avoidance operation unit that allows operators to quickly change the operational status of spindle, feed, and coolant devices without powering off, enabling immediate abnormality prevention through rotational speed adjustments, feed speed changes, or device stops, thereby preventing workpiece damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the emergency stop button is operated to power off the machine tool, then the entire machine tool is operationally stopped to avoid abnormality, but the carriage falls slightly by gravity causing workpiece interference and damage
Solution Approach 1:
The control unit detects abnormal sounds or vibrations before they cause severe damage and automatically executes countermeasures (stopping feed motion, adjusting spindle speed, separating tool and workpiece) to prevent the harmful effect of workpiece damage, rather than simply powering off the entire machine tool which would cause carriage fall
Solution Approach 2:
The control unit proactively monitors machining parameters and automatically takes preventive actions (stopping feed, adjusting speed, separating tool-workpiece) when abnormalities are detected, before the abnormality escalates to cause workpiece damage, thereby avoiding the need for emergency power-off that would cause carriage fall
2Reliability
If the operator moves to the main operation panel to operate abnormality avoidance, then the machine tool can perform abnormality avoidance operation, but the time from abnormality occurrence to operator intervention is lengthened
Solution Approach 1:
The machine tool system performs self-diagnosis by detecting abnormal sounds or vibrations through its sensors and automatically executes abnormality avoidance operations (stopping feed, adjusting spindle speed, separating tool and workpiece) without requiring operator intervention, thereby eliminating the time delay associated with operator movement and manual operation
3Object-affected harmful factors
If the feed device pulls up the carriage to prevent workpiece damage during emergency stop, then workpiece interference is avoided, but the operation takes place unexpectedly causing workpiece damage depending on timing
Solution Approach 1:
The control unit continuously monitors machining parameters including abnormal sounds and vibrations, and based on this real-time feedback, intelligently determines the appropriate response (stopping feed motion, adjusting spindle speed, or separating tool and workpiece) to avoid workpiece damage without causing unexpected harmful effects
Solution Approach 2:
The control unit detects abnormalities before they cause severe damage and automatically executes countermeasures (stopping feed motion, adjusting spindle speed, separating tool and workpiece) to prevent the harmful effect of workpiece damage, rather than simply powering off the entire machine tool which would cause carriage fall
Data Source
AI summary
[Problem] To provide a machine tool including a machine tool body including a spindle device, a feed device, and a machining auxiliary device, an additional device, a main operation panel, a sub-operation panel for manual operation of the additional device, and a controller, wherein when a predetermined abnormality occurs in the machine tool body while an operator is working at the additional device, the predetermined abnormality is quickly avoided without damaging a workpiece due to interference with a tool.[Solution] A sub-operation panel 40 has an abnormality avoidance operation unit 43 and a controller 100 is configured to be able to, when receiving an operation signal of the abnormality avoidance operation unit 43 from the sub-operation panel 40 during automatic operation based on an NC program, implement abnormality avoidance operation of a machine tool body 1 by changing an operational status of at least one of a spindle device 17, a feed device 16, and a machining auxiliary device 18 in accordance with the operation signal without powering off the machine tool 1.