Machine Tool Burr Removal Using Visual Sensor Detection
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Solution Overview
Problem
Existing machine tools face inefficiencies in burr removal due to the need for frequent air cuts and manual adjustments when dealing with burrs at non-main axis directions or outside the tool's movable range, and robots struggle with torque and tool size limitations, leading to prolonged working times.
Innovation Solution
A machine tool system utilizing visual sensors to assess burr locations and dimensions, determining whether to perform burring with the machine tool or a robot, and selecting appropriate tools to generate efficient working paths, thereby optimizing burr removal processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If burring is performed on all workpieces using the same program created from the largest burr, then consistency is maintained, but air cut (idle operation) occurs frequently resulting in wasted time
Solution Approach 1:
The system performs preliminary detection of burr conditions using visual sensors before burring operations, and pre-calculates appropriate working paths and parameters for different burr sizes and locations, eliminating the need for conservative uniform programming and reducing idle air cut operations
Solution Approach 2:
The system dynamically adjusts burring programs and working paths based on actual burr detection results for each workpiece, rather than using static uniform programs, allowing optimization of cutting parameters and path planning for each specific burr condition to eliminate wasted motion
2Productivity
If burring is performed from the main axis direction, then the machine tool operates efficiently, but burrs at non-main axis directions or locations cannot be accessed
Solution Approach 1:
The system introduces multi-dimensional working path planning that includes not only the main axis direction but also lateral and angular approaches, enabling the tool to access burrs at various locations and orientations by calculating optimized paths in multiple spatial dimensions
Solution Approach 2:
The system creates a universal burring capability that can handle burrs at any location and orientation on the workpiece by integrating multiple working approaches and path planning strategies, making the machine tool equally effective for both main axis and non-main axis burrs
3Adaptability or versatility
If a robot is used for burring, then flexibility in handling various burr locations and directions is improved, but torque limitations and tool size constraints reduce working capability on large burrs
Solution Approach 1:
The system applies partial action by using the robot only for burrs that are inaccessible to the main machine tool or require flexible positioning, while leaving large burrs that require high torque to the main machine tool, thus optimizing the division of labor based on each system's strengths
Data Source
AI summary
A machine tool of the present invention includes: a visual sensor that takes an image of unworked workpiece; an unworked workpiece shape information storing unit that stores unworked workpiece shape information obtained by the visual sensor; a worked workpiece shape information storing unit in which worked workpiece shape information is stored; a burr information calculating unit that recognizes a burr by comparing the unworked workpiece shape information with the worked workpiece shape information; a burr determining unit that determines the burr based on conditions including at least one of the location and the direction of the burr in the workpiece; a working method judging unit that decides whether or not to perform burring with a tool of the machine tool based on the determination result concerning the burr; and a working path generating unit that generates a working path for removing the burr judged to be a burr on which burring is to be performed with the tool.