Machine Tool Abnormality Monitoring via Optical Reflection Detection
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Solution Overview
Problem
Existing machine tool monitoring systems face difficulties in accurately distinguishing abnormal operations among multiple machine tools, leading to potential overlooking of critical alerts and unreliable monitoring, especially when multiple tools are present in a workplace.
Innovation Solution
A machine tool operation monitoring system that uses a camera to detect abnormal operations by projecting reflected light onto a reflecting display plate, which is moved to reflect illumination light when a machine tool's torque, speed, or moving positions exceed predetermined ranges, allowing for image-based identification of abnormalities without requiring a mechanism for signal differentiation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a wired or wireless signal transmission mechanism is used to notify abnormalities in each process unit, then the monitoring apparatus can receive abnormality notifications, but the system requires a complex mechanism for accurately distinguishing signals from different process units based on voltage, current, frequency, or waveform
Solution Approach 1:
The patent replaces the electrical signal transmission system with an optical imaging system. Instead of using wired/wireless electrical signals that require complex distinguishing mechanisms, the system uses a camera to photograph lamps on process units and an imaging device to capture and analyze the visual state of each lamp, thereby identifying which specific process unit is abnormal without needing complex signal differentiation
Solution Approach 2:
The patent creates visual copies (photographs) of the abnormality notification lamps from each process unit. The imaging device captures images of the lamps, and these image copies are transmitted to the monitoring apparatus, allowing identification of the abnormal process unit through image analysis rather than electrical signal analysis
2Device complexity
If lamps are turned on to notify abnormalities in each process unit, then signal transmission complexity is reduced, but it becomes very difficult for the person in charge to avoid overlooking a lighting lamp when multiple machine tools are installed
Solution Approach 1:
The patent implements automatic feedback by using the imaging device to continuously monitor the state of abnormality notification lamps and automatically transmit this information to the monitoring apparatus. This eliminates the need for manual observation and provides automatic feedback about which process unit is abnormal, preventing oversight even when multiple machine tools are installed
Solution Approach 2:
The patent introduces an imaging device as an intermediary between the abnormality notification lamps and the monitoring apparatus. The imaging device captures images of the lamps and transmits this visual information to the monitoring system, serving as a mediator that automatically conveys abnormality information without requiring human observation
3Ease of manufacture
If a camera photographs each machine tool and a reflecting display plate is moved to reflect illumination light when abnormalities occur, then the abnormal machine tool can be identified through image projection, but the system requires a mechanism to move the reflecting display plate to the appropriate position
Solution Approach 1:
The patent uses a reflecting display plate that changes its optical properties (reflectivity) based on the operational state of the machine tool. When an abnormality occurs, the display plate is moved to reflect illumination light, creating a visible change that the camera can detect. This optical state change provides a simple way to distinguish abnormal machines without complex signal processing
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
Enables quick identification of abnormal machine tool operations without the need for a special signal distinguishing mechanism, enhancing monitoring efficiency and reducing the risk of overlooking critical alerts.
Implementation Method 1
a reflecting display plate provided for each machine tool, the reflecting display plate being moved to a position where the reflecting display plate can reflect illumination light in a plant and project the reflected light onto the camera photographing each machine tool
Data Source
Figure 1
AI summary
[Problem to be Solved] Providing a machine tool operation monitoring system that identifies a machine tool breaking out an operation abnormality without requiring any special accurate distinguishing signal. [Solution] A machine tool operation monitoring system which detects an abnormal operation of a machine tool 1 and in which when the operation of each machine tool 1 exceeds a normal operating range of each machine tool 1 and/or when moving state of a constituent portion of the machine tool 1 and a material exceeds a normal range, wherein the machine tool 1 breaking out an operation abnormality is identified to solve the problem by any one of the following operations: a. monitoring an image obtained by projecting reflected light from a reflecting display plate 22 provided for each machine tool 1 onto a camera 31; and b. monitoring a difference in projecting direction of emitted light from a lamp 21 provided for each machine tool 1 onto an optical sensor 32.