Machine Tool Diagnosis Architecture for Low-Load Abnormality Detection
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Solution Overview
Problem
Existing machine tool diagnosis systems require separate devices for rough and detailed abnormality diagnosis, leading to high processing loads on the controller and decreased operator-friendliness due to separate input operations and notifications.
Innovation Solution
A diagnosis system where a signal processing device, separate from the machine tool controller, processes sensor signals for both rough and detailed abnormality diagnosis, with input operations and notifications centralized within the machine tool, allowing for efficient processing and improved user interface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the controller of the machine tool incorporates all the configuration of the abnormality diagnosis device, then operator-friendliness is improved by centralizing input operations and notifications, but the processing load on the controller becomes significantly heavy due to heavy-load processings such as frequency analysis
Solution Approach 1:
The system divides the abnormality diagnosis device into two independent parts: a signal processing device for heavy-load frequency analysis and a controller for machine tool control and user interface management. This segmentation allows each device to specialize in its function, reducing the processing load on the controller while maintaining operator-friendliness through centralized input operations and notifications.
Solution Approach 2:
The signal processing device acts as an intermediary between the sensor and the controller. It performs heavy-load frequency analysis on sensor signals and transmits only the analysis results to the controller, thereby mediating the heavy processing burden and allowing the controller to focus on control operations and user interface management.
2Power
If separate devices are used for rough and detailed abnormality diagnosis, then the processing load on the controller is reduced, but operator-friendliness degrades due to separate input operations and notifications
Solution Approach 1:
The system merges the user interface functions (input operations and notifications) into the machine tool controller, while keeping the heavy processing functions separate in the signal processing device. This merging of interface functions with the controller maintains operator-friendliness even though the processing device is separate, creating a unified user experience despite the distributed architecture.
3Power
If a separate signal processing device is used for abnormality diagnosis, then the processing load on the controller is reduced, but device complexity increases due to additional components
Solution Approach 1:
The signal processing device is designed with multi-functionality, serving both as a heavy-load processing unit for frequency analysis and as a bridge between the sensor and controller. This universal device handles multiple tasks (signal acquisition, frequency analysis, result transmission), reducing the need for multiple specialized components and thereby managing system complexity.
Data Source
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AI summary
A machine tool includes a component, a sensor, a signal processing device, a controller, and an Input-Output device. The component is variable in state based on an operation of an actuator of the machine tool. The sensor is configured to detect the state of the component. The signal processing device is configured to process a signal from the sensor. The controller is configured to control the operation of the actuator. The Input-Output device is configured to receive an instruction for the controller to control the actuator to conduct the operation. The Input-Output device is configured to notify an operation status of the actuator. The signal processing device is configured to, based on the signal, generate rough state-description data relevant to an occurrence of an abnormality in the component, and configured to transmit the generated rough state-description data to the controller. The signal processing device is configured to, based on the signal, generate detailed state-description data that is for identifying an abnormal part in the component and that is more informative than the rough state-description data. The signal processing device is configured to transmit the generated detailed state-description data to a remote monitor apparatus that is configured to analyze the state of the component. Based on the rough state-description data transmitted to the controller, the Input-Output device is configured to notify an operator of whether the abnormality is occurring in the component.