Machine Tool Control for Fast Rotary Tool Model Creation
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Solution Overview
Problem
Existing machine tool measurement methods are inefficient for tools with complex shapes, such as drills and end mills with helical grooves, and are time-consuming for tools with complicated side surfaces, making it difficult to generate accurate tool models for machining centers that use multiple tools sequentially.
Innovation Solution
A machine tool controller that uses an imaging device to capture image data of the tool shank and holder, generating model data from nominal dimensions of the blade, allowing for quick and accurate creation of tool models by separating the tool shank/holder and blade model data, which are then combined to generate rotary tool model data.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If laser beam measurement is used for tools with complicated side surface shapes, then measurement accuracy is improved, but measurement time increases significantly
Solution Approach 1:
The tool model generation process is segmented into two distinct parts: the blade portion (with complex geometry) and the tool shank/holder portion (with simpler geometry). This segmentation allows different measurement approaches to be applied to each part, optimizing both accuracy and efficiency.
Solution Approach 2:
The complex blade portion is extracted from the overall tool model generation process. Instead of measuring the entire tool with time-consuming laser beam methods, only the simpler tool shank/holder is measured using imaging devices, while the blade dimensions are obtained from nominal values stored in advance.
2Measurement precision
If contact-type measurement pins are used for rotating grindstones, then outer diameter and thickness can be measured, but tools with helical grooves such as drills and end mills cannot be measured
Solution Approach 1:
The mechanical contact-type measurement pins are replaced with an optical imaging device. This substitution allows non-contact measurement of tools with complex geometries including helical grooves, significantly expanding tool type compatibility while maintaining measurement capability for outer diameter and length.
3Measurement precision
If detailed image-based measurement is performed for the entire rotary tool, then accurate model data can be generated, but the process becomes time-consuming for tools with complicated shapes
Solution Approach 1:
The tool model generation process is segmented into two distinct parts: the blade portion (with complex geometry) and the tool shank/holder portion (with simpler geometry). This segmentation allows different measurement approaches to be applied to each part, optimizing both accuracy and efficiency.
Solution Approach 2:
Nominal dimensions of the blade are stored in advance in the storage unit. This preliminary preparation eliminates the need for time-consuming image-based measurement of the blade portion during actual tool modeling, significantly improving model generation speed.
4Measurement precision
If conventional measurement methods are used for multiple tools in a machining center, then each tool can be measured accurately, but the sequential tool exchange process becomes inefficient
Solution Approach 1:
The complex blade portion is extracted from the overall tool model generation process. Instead of measuring the entire tool with time-consuming laser beam methods, only the simpler tool shank/holder is measured using imaging devices, while the blade dimensions are obtained from nominal values stored in advance.
Solution Approach 2:
The system uses pre-stored nominal dimension data as a template or copy for the blade portion, eliminating the need to remeasure these dimensions for each tool. This copying approach maintains consistency and accuracy while dramatically reducing measurement time across multiple tool exchanges.
Data Source
AI summary
This control device of a machine tool is provided with: a storage unit which stores in advance a nominal diameter and a nominal length of a blade part of a rotary tool; an image-capturing instruction unit which outputs an image-capturing instruction to an image-capturing device; a model creation unit which generates model data of the blade part of the tool on the basis of the nominal diameter and the nominal length stored in the storage unit, generates model data of a tool shank and holder on the basis of an image stored in the image-capturing device, and creates model data of the rotary tool on the basis of the generated model data of the blade part and the generated model data of the tool shank and holder.