Machine Tool Accuracy Analysis for Reliable Compensation Correction
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Solution Overview
Problem
Existing machine tool accuracy analysis systems lack the ability to confirm the reduction degree of machine accuracy and the effectiveness of compensation data adjustments, leading to unnecessary adjustments and wasted time and cost.
Innovation Solution
An accuracy analysis system for machine tools that includes a control unit, data server, data communication unit, data analyzer, corrected machine accuracy calculation unit, and data display unit, allowing users to confirm machine accuracy before and after compensation data adjustments, and perform analyses using data from multiple machines with correlated information.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If compensation data is corrected based on limited measurement data taken when machining is stopped, then machine accuracy can be adjusted, but the reliability of the correction value is reduced due to insufficient data
Solution Approach 1:
The system collects and stores accuracy data during the machining process before any correction is made. This preliminary data collection during normal operation provides a sufficient data foundation for reliable correction value calculation, eliminating the need to rely on limited post-stop measurement data.
Solution Approach 2:
The system continuously collects accuracy data during machining operations rather than interrupting the process for measurement. This continuous data collection ensures sufficient data volume and maintains the productive action while gathering the necessary information for accurate correction.
2Measurement precision
If service personnel visit to measure and analyze machine accuracy, then accurate measurement can be performed, but time and cost are wasted when machine accuracy is not actually reduced
Solution Approach 1:
The system enables users to independently determine whether machine accuracy adjustment is needed by automatically analyzing collected accuracy data and calculating correction values. This self-service capability eliminates the need for service personnel visits in cases where only software correction is required, saving time and cost while maintaining measurement precision through automated analysis.
Solution Approach 2:
The system provides feedback to users about the current machine accuracy status and the effectiveness of correction values through the display unit. This feedback mechanism allows users to make informed decisions about whether adjustment work is necessary, preventing unnecessary service calls and optimizing the use of measurement resources.
3Manufacturing precision
If service personnel visit to perform adjustment work, then machine accuracy can be improved, but cost and time increase for cases where software correction suffices
Solution Approach 1:
The system allows users to independently apply correction values to compensate for machine accuracy reductions through software. This self-service correction capability handles cases where accuracy degradation can be addressed through data processing, eliminating the need for service personnel visits and reducing costs while maintaining manufacturing precision.
Solution Approach 2:
The system corrects machine accuracy by changing parameters (compensation data) rather than performing physical adjustments. This parameter-based correction approach is easier to implement and can be performed by users without specialized training, reducing the need for service personnel while maintaining manufacturing precision.
Data Source
AI summary
An accuracy analysis system for a machine tool includes: a control unit, a data server, a data communication unit, a data analyzer, a corrected machine accuracy calculation unit, and a data display unit. The control unit stores preliminarily obtained accuracy data regarding a machine accuracy, compensation data for compensating for an error, and machine information. The data communication unit transmits the accuracy data, the compensation data, and the machine information to the data server. The data analyzer uses the accuracy data and the compensation data in the data server to obtain a compensation data correction value as a correction value of the compensation data and expected accuracy data when the compensation data correction value is applied. The corrected machine accuracy calculation unit calculates a post-correction machine accuracy from the expected accuracy data. The data display unit displays the post-correction machine accuracy calculated by the corrected machine accuracy calculation unit.