Movable Visual Sensor Monitoring in Machine Tools With Swarf Obstruction
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Solution Overview
Problem
Machine tools face challenges in monitoring machining surfaces due to limited sensor attachment locations and obstacles like swarf and cutting fluid, which obstruct the view of visual sensors, preventing effective monitoring of the machining portion.
Innovation Solution
A machine tool equipped with a visual sensor and a controller that uses processors and memory to position the sensor via an in-machine robot, avoiding obstacles by analyzing images, electrical resistance, or force sensors to maintain a clear view of the machining area, allowing continuous monitoring without manual adjustment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a visual sensor is attached to a fixed portion such as the cover, then the sensor structure is simple, but it cannot avoid obstacles and monitor the machining portion
Solution Approach 1:
The visual sensor is mounted on a movable platform that can dynamically adjust its position and orientation to avoid obstacles like swarf and cutting fluid. The platform includes drive means actuated by a controller to move the sensor to appropriate viewing positions, transforming a static sensor system into a dynamic one that adapts to changing machining conditions.
Solution Approach 2:
The system uses the visual sensor itself to detect obstacles and determine its own repositioning needs. The sensor captures images, the controller analyzes them to detect obstacles, and automatically commands the platform to move to a new position where the machining portion is visible without obstruction, enabling the system to self-correct without external intervention.
2Area of stationary object
If multiple sensors are provided to cover the entire machining surface, then monitoring coverage is improved, but cost increases
Solution Approach 1:
Instead of using multiple static sensors to cover different areas, a single visual sensor is mounted on a movable platform that can dynamically reposition itself to view different portions of the machining area. This dynamic positioning allows one sensor to effectively cover the entire machining surface over time, eliminating the need for multiple sensors.
Solution Approach 2:
The movable platform enables a single visual sensor to perform multiple functions by positioning it at different locations and orientations. The sensor can monitor various machining portions, avoid different types of obstacles, and adapt to different machining scenarios, making one sensor universally applicable throughout the machining process.
3Adaptability or versatility
If the visual sensor is attached to a table, spindle, or tool post, then the sensor can move with the machining components, but it cannot freely reposition to avoid obstacles during machining
Solution Approach 1:
The visual sensor is mounted on a movable platform that provides dynamic repositioning capability independent of the machining components' motion. The platform includes drive means that can freely adjust the sensor's position and orientation based on real-time obstacle detection, allowing the sensor to adapt to changing conditions without being constrained to fixed movement patterns.
Solution Approach 2:
The system implements a feedback loop where the visual sensor continuously monitors the machining area, the controller analyzes the captured images to detect obstacles, and automatically commands the platform to reposition the sensor to an optimal viewing position. This closed-loop control enables the sensor to freely reposition itself in response to real-time conditions, maintaining monitoring capability despite obstacle presence.
Data Source
AI summary
A machine tool is disclosed which continues monitoring even when there is an obstacle such as swarf or a cutting fluid between a machining portion to be monitored and a visual sensor. A visual sensor is attached to an in-machine robot which is movable in a machine tool. A controller operates the visual sensor while judging influences of the swarf and the cutting fluid, automatically judges an orientation experiencing less influence, and executes monitoring from an optimum direction.