Machine Tool Program Correction After Tool Replacement
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Solution Overview
Problem
Machine tools under NC control face challenges in automatically correcting machining programs during tool replacement, leading to inefficiencies and increased operator burden due to manual trial machining and potential dimensional errors.
Innovation Solution
A machine tool system that outputs a tool replacement signal, temporarily machines a workpiece to a target dimension, measures the actual dimension, detects any dimensional differences, and automatically corrects the machining program to ensure precise machining, reducing the need for manual corrections and improving machinability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual trial machining is performed after tool replacement, then machining accuracy can be verified, but operator burden increases and productivity decreases
Solution Approach 1:
The machine tool system automatically performs trial machining and measurement without operator intervention. The control unit autonomously executes the trial machining program, collects measurement data from the measurement device, calculates dimensional differences, and generates correction amounts, enabling the system to self-correct machining programs after tool replacement
Solution Approach 2:
The system performs trial machining as a preliminary step before actual production machining. By conducting trial machining and obtaining measurement data in advance, the system pre-calculates correction amounts and updates the machining program before full-scale production, preventing dimensional errors in subsequent machining operations
Solution Approach 3:
The system establishes a feedback loop where measurement data from trial machining is fed back to the control unit. The control unit calculates dimensional differences between measured values and target values, determines correction amounts, and updates the machining program accordingly, creating a closed-loop control system that automatically compensates for tool wear and replacement variations
2Manufacturing precision
If manual correction of machining programs is performed, then dimensional accuracy can be adjusted, but time is lost and efficiency decreases
Solution Approach 1:
The system replaces manual mechanical correction operations with automated computational processes. The control unit automatically calculates correction amounts based on measurement data and programmatically updates the machining program, eliminating the need for operators to manually adjust parameters and reducing correction time
Solution Approach 2:
The control unit acts as an intermediary between the measurement device and the machining program. It receives measurement data, automatically processes the information to calculate dimensional differences and correction amounts, and generates updated machining programs, eliminating the need for direct manual intervention in the correction process
3Productivity
If automated correction system is implemented, then productivity increases, but device complexity increases
Solution Approach 1:
The control unit performs multiple functions: it controls the machining operation, manages tool replacement signaling, coordinates with the measurement device, calculates correction amounts, and updates machining programs. By consolidating these diverse functions into a single control unit, the system achieves automation without proportionally increasing overall system complexity
Solution Approach 2:
The system merges the trial machining process, measurement process, data processing, and program correction into an integrated automated workflow. The control unit coordinates all these operations seamlessly, combining multiple discrete functions into a unified automated system that improves productivity without requiring separate complex subsystems for each function
4Productivity
If trial machining is eliminated, then productivity improves, but machining precision may deteriorate
Solution Approach 1:
The system performs trial machining as a preliminary quality assurance step before full production machining. This preliminary operation allows the system to verify dimensional accuracy, calculate correction amounts, and update the machining program, ensuring that subsequent production machining operates with corrected parameters for optimal precision
Solution Approach 2:
The trial machining process provides critical feedback information about actual tool performance and dimensional accuracy. The measurement device captures this feedback data, which the control unit uses to calculate correction amounts and update the machining program, creating a feedback mechanism that maintains precision without requiring extensive trial machining
Data Source
AI summary
A machine tool having a function of automatically correcting a machining program in tool replacement includes: a signal output unit that outputs a signal when a tool is replaced; a machining unit that temporarily machines a workpiece to a predetermined target dimension using the replaced tool; a measurement unit that measures an actual dimension of the temporarily machined workpiece; a detection unit that detects a dimensional difference between the measured actual dimension and the target dimension; and an automatic correction unit that automatically corrects the machining program based on the dimensional difference, wherein the machining unit actually machines the workpiece based on the automatically corrected machining program.