Machine Tool Axis Deviation Judgement From Time-Series Sensor Data
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Solution Overview
Problem
Current methods for determining axis position deviations in machine tools often require manual intervention and unnecessary adjustments, leading to increased cycle time and operational costs, even when adjustments are not necessary.
Innovation Solution
An automated adjustment necessity determination device that acquires and analyzes time-series data from sensors to assess whether axis position adjustments are required, using threshold values and machine learning algorithms to make judgments about necessary corrections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual determination of axis position deviation is performed by operator, then adjustment can be made when needed, but cycle time increases due to unnecessary adjustments and manual intervention
Solution Approach 1:
The system automatically determines whether axis position adjustment is needed by analyzing time-series data from sensors, eliminating the need for manual operator judgment. The determination unit autonomously compares measured values against reference values and decides whether adjustment is necessary, allowing the system to serve itself without human intervention and avoiding unnecessary adjustments that waste cycle time
Solution Approach 2:
The system continuously acquires time-series data from sensors during machining operations and feeds this information back to the determination unit. This feedback mechanism enables real-time monitoring of axis position deviations and allows the system to make informed decisions about whether adjustment is needed, improving both reliability and productivity by basing decisions on actual measured conditions rather than manual estimation
2Ease of operation
If automatic adjustment is performed without determination, then operator intervention is eliminated, but cycle time increases due to unnecessary automatic adjustments
Solution Approach 1:
The determination unit autonomously evaluates whether adjustment is needed by comparing sensor data against reference values, enabling the system to self-manage the adjustment decision-making process. This eliminates operator burden while avoiding unnecessary automatic adjustments that would extend cycle time, as the system only performs adjustments when actual deviation exceeds acceptable thresholds
Solution Approach 2:
Instead of performing adjustment in all cases, the system applies partial action by conducting adjustment only when the determination unit identifies actual deviation beyond reference values. This selective approach maintains ease of operation through automation while preventing the excessive action of unnecessary adjustments that would waste cycle time
3Extent of automation
If camera or imaging device is used to detect axis deviation, then automatic detection is achieved, but device cost increases due to unnecessary imaging equipment
Solution Approach 1:
The system uses existing sensors already present in the machine tool for their primary functions to also detect axis position deviations. The time-series data from these multi-functional sensors is reused by the determination unit for deviation detection, achieving automatic detection without adding specialized imaging equipment like cameras, thus maintaining automation while avoiding increased device complexity and cost
Solution Approach 2:
Instead of using expensive specialized imaging devices to detect axis deviation, the system creates a functional copy by repurposing data from existing sensors. The determination unit processes time-series data from standard sensors to infer axis position information, achieving the same detection capability as specialized imaging equipment would provide but using already-available data sources, thereby avoiding additional equipment costs
Data Source
AI summary
An adjustment necessity determination device is an adjustment necessity determination device that makes a determination, after a workpiece is machined, about a necessity to make an adjustment of a deviation of the axis position of each axis of a machine tool that has performed the machining and includes: a data acquisition unit that acquires a physical quantity relating to a cause of a deviation of the axis position of each axis of the machine tool, the physical quantity observed at the time of the machining; a time-series data storage unit that stores the physical quantity as time-series data; and an adjustment necessity judgement unit that makes a judgment about a necessity to make an adjustment of a deviation of the axis position of each axis of the machine tool based on the time-series data.