Machine Tool Control System for Vibration Failure Analysis
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Solution Overview
Problem
Machine tools often produce stripe patterns on machined surfaces due to vibrations, and existing detection methods are inadequate for analyzing the cause and location of these failures effectively.
Innovation Solution
A control system that associates chronological drive axis control data with spatial machined surface measurement data using a numerical control system, including a data processing device that acquires and processes position, torque, and load information to detect and identify failure locations on the machined surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If vision sensor and image processing are used to detect failures on machined surfaces, then failure detection capability is improved, but the ability to analyze cause and location effectively deteriorates due to lack of correlation with drive axis control data
Solution Approach 1:
The patent merges chronological drive axis control data with spatial machined surface measurement data by associating them through coordinate transformation. The data associating processing portion transforms coordinate systems and correlates control data (positions, speeds, accelerations) with measurement data (surface coordinates, failure locations, depths) to create integrated information that enables both detection and cause analysis.
Solution Approach 2:
The patent introduces a data associating processing portion as an intermediary that bridges the gap between drive axis control data and machined surface measurement data. This intermediary performs coordinate system transformation and data correlation, enabling effective information exchange and integration between the two data sources for comprehensive failure analysis.
2Loss of information
If chronological control data and spatial measurement data are associated through coordinate transformation, then cause analysis capability is improved, but data processing complexity increases
Solution Approach 1:
The patent performs preliminary coordinate system transformation on drive axis control data before association with measurement data. By pre-processing the control data to transform coordinates and organize temporal information in advance, the system reduces the complexity of the subsequent association process and enables more efficient data integration.
3Measurement precision
If detailed chronological control data is collected and associated with measurement data, then failure location precision is improved, but data acquisition and processing time increases
Solution Approach 1:
The patent extracts only the necessary chronological control data (positions, speeds, accelerations at relevant time points) required for failure location identification, rather than processing all available control data. This selective extraction reduces data processing time while maintaining sufficient precision for locating and analyzing failures.
Data Source
AI summary
A control system of a machine tool which machines a work includes: a numerical control device which controls the drive axis of the machine tool based on control data; a machined surface measurement device which measures the machined surface of the work; and a data processing device, and the data processing device includes a drive axis control data acquisition portion which acquires, from the numerical control device, the chronological control data when the work is machined; a machined surface measurement data acquisition portion which acquires spatial machined surface measurement data after the machining of the work measured by the machined surface measurement device; and a data-associating processing portion which associates the chronological control data acquired by the drive axis control data acquisition portion and the spatial machined surface measurement data acquired by the machined surface measurement data acquisition portion with each other.