Machine Tool Maintenance Scheduling Using Thermal Distortion Data

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Solution Overview

Problem

Conventional machine tool management systems fail to accurately determine machining failures due to thermal distortion and require fixed inspection schedules, which can lead to mismatched maintenance and inspection cycles, limiting their ability to adapt to actual service conditions.

Innovation Solution

An advanced machine tool management system that collects and analyzes data from multiple machine tools, including estimated thermal distortion, using a maintenance period model and refinement algorithm to determine machining status and adjust maintenance schedules dynamically, and employs a robot with detecting sensors to inspect parts and determine actual service conditions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If fixed inspection schedules are used, then maintenance planning is simplified, but the system cannot adapt to actual service conditions and may miss machining failures

Engineering Contradiction:

Improveadaptability to actual service conditionsVSAvoidmaintenance schedule complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent implements dynamic maintenance scheduling by continuously updating the maintenance period model based on actual operating conditions and thermal distortion data. The system transitions from fixed schedules to adaptive schedules that automatically adjust inspection intervals according to real-time machine tool performance, resolving the contradiction between adaptability and complexity.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system incorporates feedback mechanisms where thermal distortion measurements and operating condition data are fed back into the maintenance period model. This feedback loop enables the system to learn from actual service conditions and refine maintenance schedules accordingly, achieving adaptability without excessive complexity through iterative optimization.

Inventive Principle:

Principle #23Feedback

2Measurement precision

If conventional data collection methods are used, then system simplicity is maintained, but machining failures due to thermal distortion cannot be accurately determined

Engineering Contradiction:

Improvethermal distortion measurement accuracyVSAvoiddata collection system complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent introduces thermal distortion sensors as intermediary measurement devices that specifically capture thermal distortion data. These sensors act as mediators between the machine tool and the analysis system, providing precise thermal distortion measurements without requiring complete system redesign, thus achieving high measurement precision with controlled complexity.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The system replaces conventional mechanical measurement methods with optical or sensor-based thermal distortion detection. This substitution enables non-contact, high-precision measurement of thermal distortion, improving measurement accuracy while avoiding the complexity of mechanical measurement systems.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If preset inspection cycles are used, then maintenance planning is straightforward, but the system cannot determine actual service conditions of parts

Engineering Contradiction:

Improveaccuracy of service condition determinationVSAvoidmaintenance operation simplicity

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The system implements self-service functionality where the maintenance period model automatically determines optimal inspection times and service conditions based on collected data. The system serves itself by autonomously generating maintenance schedules without requiring manual intervention, thereby improving reliability while maintaining ease of operation through automation.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent dynamically changes maintenance parameters such as inspection intervals and thresholds based on actual operating conditions and thermal distortion data. By adjusting these parameters adaptively rather than using fixed values, the system achieves accurate service condition determination while simplifying operations through data-driven automation.

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS11614728B2Machine tool management system that obtains a next maintenance period from a maintenance period model and a refinement algorithm

Publication Date: 2023.03.28 FANUC LTD

AI summary

A machine tool management system connects an external server and a large number of NC devices controlling the external server and respective machine tools through a network. The system collects several kinds of signal data from the NC device of each machine tool to the external server. In the system, the external server stores a maintenance period model and a refinement algorithm and obtains a next maintenance period from the maintenance period model.