Machine Tool Control for Fast Rotary Tool Model Generation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods struggle to accurately and efficiently generate tool models for rotary tools with complex shapes, such as drills and end mills, due to the time-consuming nature of laser beam measurements and the inability to measure tools with helical grooves in numerically controlled machine tools.
Innovation Solution
A machine tool controller generates tool models by combining tool shank and holder model data from captured image data and nominal dimensions, using a backlight imaging system to create model data for rotary tools, which are then used for interference simulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If laser beam measurement is used to measure the outer diameter and length of a tool, then measurement precision is improved, but measurement time increases significantly making it unsuitable for sequential tool exchange operations
Solution Approach 1:
The patent replaces the mechanical laser beam measurement system with an optical imaging system using a camera and illumination device. This substitution allows for rapid capture of tool images without the time-consuming point-by-point scanning required by laser measurement, thereby reducing measurement time while maintaining adequate precision for tool modeling.
Solution Approach 2:
The patent creates a visual copy of the tool by capturing its image with a camera instead of physically measuring it with laser beams. This optical copying approach enables rapid documentation of tool geometry without the time penalty of sequential laser measurement points, allowing for quick tool model generation in sequential exchange operations.
2Productivity
If contact-type measurement pins are used to measure a rotating grindstone, then measurement speed is improved, but the method cannot measure tools with helical grooves such as drills and end mills
Solution Approach 1:
The patent replaces the mechanical contact measurement pins with a non-contact optical imaging system. This allows the system to measure tools with complex geometries including helical grooves, flutes, and irregular surfaces that cannot be accessed by contact pins, thereby increasing versatility while maintaining rapid measurement capability through image capture.
Solution Approach 2:
The patent creates a visual record of the tool's complete geometry through imaging, allowing measurement of complex features like helical grooves without physical contact. This optical copying approach captures the entire tool surface in a single or few images, enabling measurement of diverse tool types that contact methods cannot handle.
3Manufacturing precision
If detailed image-based modeling is performed for the entire rotary tool including complex blade shapes, then model accuracy is improved, but processing time and complexity increase significantly
Solution Approach 1:
The patent divides the rotary tool model into two segments: the tool shank/holder portion which is modeled from captured image data, and the blade portion which uses nominal dimensions stored in advance. This segmentation allows the complex blade geometry to be simplified while maintaining overall model accuracy for interference simulation purposes, significantly reducing processing time.
Solution Approach 2:
The patent applies partial modeling by using nominal blade dimensions rather than detailed captured geometry. This partial action approach provides sufficient accuracy for interference simulation without the excessive processing required for complete detailed modeling, achieving the right balance between model fidelity and generation speed.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach allows for quick, easy, and accurate generation of rotary tool models, enabling efficient interference simulation without the need for detailed image-based modeling of complex shapes, reducing measurement time and improving tool management in machine tools.
Implementation Method 1
image data obtained by imaging the rotary tool 5
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
This control device (100) of a machine tool is provided with: a storage unit (108) which stores in advance a nominal diameter and a nominal length of a blade part of a rotary tool; an image-capturing instruction unit (102) which outputs an image-capturing instruction to an image-capturing device (126); a model creation unit (106) 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.