Machine Tool End-Stop Load Check for Drive Unit Failure Detection
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Solution Overview
Problem
Machine tools face accuracy and safety issues due to wear, material fatigue, or defects in drive unit components, leading to potential breakages that can cause hazardous uncontrolled movements, especially in vertically running drive units, posing risks to operators and machine integrity.
Innovation Solution
A method where a machine controller moves a component into an end position where it rests against a first stop, and continues to exert force to detect any further movement, outputting an error message if movement occurs, using a second stop to prevent unintended movement and ensure safety, allowing for detection of potential accuracy and safety problems before they occur.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a drive unit is used to move a component along a movement path, then productivity and machining capability are improved, but reliability deteriorates due to wear, material fatigue, or defects in drive unit components leading to potential breakages
Solution Approach 1:
The patent applies preliminary action by performing a strength test before normal operation. The machine controller moves the component to an end position and applies additional force through the drive unit to detect any unwanted movement that would indicate component weakness. This preventive testing identifies potential failures before they occur during actual machining operations.
Solution Approach 2:
The patent implements feedback by using sensors to detect unwanted movement of the component or drive unit during the strength test. The machine controller receives this feedback and outputs an error message if movement is detected, indicating component weakness. This closed-loop feedback system enables real-time monitoring and early warning of potential failures.
2Measurement precision
If the drive unit continues to exert force after reaching the end position, then detection of component weakness is improved, but harmful factors increase due to potential damage from uncontrolled movements
Solution Approach 1:
The patent applies beforehand cushioning by providing a stop at the end position that prevents the component from moving beyond its intended travel range. This mechanical cushioning protects against harmful uncontrolled movements while still allowing the drive unit to exert force for detection purposes. The stop absorbs any excess force or movement, preventing damage to the component or surrounding equipment.
3Reliability
If a stop is provided between the component and frame part, then safety is improved by preventing uncontrolled movements, but device complexity increases due to additional components
Solution Approach 1:
The patent applies universality by designing the stop to serve multiple functions: it defines the end position of the component's travel path, provides mechanical cushioning to prevent uncontrolled movements, and acts as a reference point for the strength test. This multi-functional design prevents safety hazards without significantly increasing device complexity, as the stop is an integral part of the existing machine structure.
Data Source
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Figure 3
AI summary
The invention relates to a machine tool for machining tools, the machine tool comprising: a machine frame (22); at least one component (63) which can be moved along a movement path (72) by means of a drive unit (62) actuated by an external force; at least one frame part (83) which is connected to the machine frame (22) and which is located at an end position (87) in the movement path (72) of the component (63); and at least one first stop (85) via which the component (63) located in the end position (87) is in contact with the frame part (83), wherein the first stop (85) lies outside the movement path (72) (figure 3).