Machine Tool Motor Diagnosis with Environment-Adaptive Thresholds
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Solution Overview
Problem
Existing machine tool diagnostic methods become inaccurate when the environment changes, affecting the responsivity of servo motors and leading to incorrect abnormality diagnosis.
Innovation Solution
A diagnostic apparatus and method that acquire state information from motors and measure environmental physical quantities, comparing them to stored normal ranges to accurately identify machine tool abnormalities, including a system with a sensor, storage unit, and judging unit to provide notifications of potential issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If fixed normal ranges are used for diagnosis, then the diagnostic system is simple to operate, but the diagnosis becomes inaccurate when environmental conditions change
Solution Approach 1:
The patent applies dynamics by making the normal range dynamic rather than fixed. The system automatically adjusts the normal range based on detected environmental conditions (temperature, humidity, vibration), allowing the diagnostic thresholds to adapt to changing operating conditions. This resolves the contradiction by maintaining high diagnosis accuracy through adaptive ranges while keeping the system relatively simple through automated adjustment without manual intervention.
Solution Approach 2:
The patent changes the parameter of the normal range based on environmental parameters. When temperature, humidity, or vibration conditions change, the system modifies the normal range values accordingly. This allows the diagnostic system to maintain accuracy across different environmental conditions while using a straightforward comparison mechanism, balancing precision with system simplicity.
2Reliability
If environmental sensing and dynamic range adjustment are implemented, then diagnosis accuracy improves under varying conditions, but the device complexity increases
Solution Approach 1:
The control unit serves multiple functions: it controls the servo motor, detects environmental conditions (temperature, humidity, vibration), adjusts the normal range based on these conditions, and performs the actual diagnosis. By making the control unit multi-functional, the patent improves diagnosis reliability through environmental adaptation while minimizing the increase in overall system complexity by reusing existing components for multiple purposes.
Solution Approach 2:
The system performs self-adjustment of the normal range based on detected environmental conditions without requiring external intervention or complex calibration procedures. The control unit automatically modifies the diagnostic thresholds to match current operating conditions, improving reliability while keeping the system relatively simple through automated self-service functionality.
Data Source
AI summary
A diagnostic apparatus includes an acquiring unit that acquires state information indicating an operational state of a motor for driving a shaft of a machine tool; a sensor that measures a physical quantity indicating an environment of the machine tool; a storage unit which stores a normal range of the state information corresponding to a value of the physical quantity; and a judging unit that, when the state information acquired by the acquiring unit is not within the normal range of the state information corresponding to the value of the physical quantity measured by the sensor, judges that the machine tool has an abnormality.