Machine Tool Temperature Sensor Fault Detection by Cross-Machine Comparison
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Solution Overview
Problem
Existing methods for detecting abnormalities in temperature sensors of machine tools are costly due to the need for multiple sensors and complex installation schemes, and they struggle to accurately determine sensor issues without increasing the number of measurement instruments.
Innovation Solution
A system that acquires and compares temperature data from multiple machine tools with equivalent environments and sensor positions to determine abnormalities based on differences in temperature data, allowing for centralized detection without the need for extensive sensor installations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple temperature sensors are installed at different positions to detect abnormalities, then abnormality detection capability is improved, but device complexity and installation cost increase
Solution Approach 1:
The patent combines temperature data from multiple existing sensors into a single reference temperature value through averaging. This merged reference value is then used to evaluate all individual sensors, eliminating the need for additional sensors while maintaining abnormality detection capability.
Solution Approach 2:
The reference temperature calculated from multiple sensors serves multiple functions: it acts as a baseline for comparing individual sensor readings, enables abnormality detection, and provides a basis for determining thermal displacement compensation values. This multi-functional use of the reference temperature reduces the need for separate detection mechanisms.
2Reliability
If multiple temperature sensors are installed at the same location to detect abnormalities, then abnormality detection capability is improved, but cost increases due to increased number of sensors
Solution Approach 1:
Instead of installing multiple physical sensors at the same location, the patent creates a virtual copy of the temperature measurement through calculation. The reference temperature is computed as an average of existing sensor readings, serving as a virtual reference point for comparing individual sensor outputs without requiring duplicate physical sensors.
Solution Approach 2:
The system uses its existing temperature sensors to generate a reference temperature that serves the dual purpose of both measurement and self-diagnosis. Each sensor's reading is compared against the reference generated collectively by all sensors, enabling the system to self-monitor for abnormalities without external additional equipment.
3Manufacturing precision
If temperature sensors are used to monitor thermal displacement, then machining precision is improved, but reliability decreases due to sensor abnormalities from cutting fluid and chips
Solution Approach 1:
The patent implements a feedback mechanism where the reference temperature (calculated from all sensors) continuously monitors individual sensor performance. When a sensor's reading deviates significantly from the reference, the system detects the abnormality and can exclude that sensor from future calculations, maintaining measurement reliability despite harsh environmental conditions.
Solution Approach 2:
The system proactively detects sensor abnormalities before they significantly impact machining precision. By continuously comparing each sensor reading against the reference temperature and identifying deviations exceeding a threshold, the system prevents faulty sensor data from compromising thermal displacement compensation and machining accuracy.
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 cost-effective and efficient detection of abnormal temperature sensors by comparing data from equivalent positions, reducing the number of required sensors and instruments while maintaining accuracy in thermal displacement estimation.
Implementation Method 1
a temperature sensor 7 provided at a specific position on the machine tool 4
Data Source
AI summary
To provide an abnormality determination apparatus, a computer readable medium, an abnormality determination system and an abnormality determination method which can simply detect an abnormality of a temperature in a machine tool without incurring cost. An abnormality determination apparatus which determines abnormality of a temperature sensor in a plurality of machine tools, in which the plurality of machine tools is equivalent machine type, is arranged in equivalent environments, are provided with a temperature sensor at equivalent positions, the abnormality determination apparatus including: a temperature data acquisition unit which acquires temperature data outputted by the temperature sensors from each of the plurality of machine tools; a comparison unit which compares the temperature data acquired by the temperature data acquisition unit; and an abnormality determination unit which determines abnormality of the temperature sensor based on a comparison result by the comparison unit.