Machine Tool Temperature Sensor Fault Detection by Pattern Comparison
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Solution Overview
Problem
Current methods for detecting abnormalities in temperature sensors of machine tools require multiple sensors, increasing costs and complexity, and are ineffective in detecting issues due to aging degradation or incorrect values without additional instrumentation.
Innovation Solution
An abnormality determination apparatus that uses a single temperature sensor, storing and comparing normal temperature patterns relative to machining time to detect anomalies, allowing for cost-effective detection of sensor abnormalities without the need for multiple sensors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple temperature sensors are arranged to detect abnormalities, then abnormality detection capability is improved, but device complexity and cost increase
Solution Approach 1:
The patent segments the abnormality detection function into two parts: a single temperature sensor for data collection, and a processing unit that divides the detection task into multiple virtual sensor perspectives through data processing and comparison operations
Solution Approach 2:
The patent creates virtual copies of temperature sensor functionality through data processing. By comparing actual sensor data with estimated data from other locations, the system replicates the effect of multiple physical sensors without requiring them
2Measurement precision
If multiple temperature sensors are installed at the same location, then abnormality detection accuracy is improved, but cost increases
Solution Approach 1:
The patent introduces data processing and estimation algorithms as intermediaries between the single physical sensor and the abnormality detection goal. These intermediaries create virtual measurement points without requiring additional physical sensors
Solution Approach 2:
The system creates virtual copies of temperature measurements at different locations through estimation algorithms, allowing comparison of multiple temperature profiles using only one physical sensor
3Device complexity
If a single temperature sensor is used, then device complexity is reduced, but abnormality detection capability deteriorates
Solution Approach 1:
The patent implements feedback mechanisms where the system continuously compares actual temperature sensor data with estimated temperature data from other locations. This feedback loop enables reliable abnormality detection by identifying deviations from expected temperature patterns
Solution Approach 2:
The system uses the single temperature sensor's data to serve multiple functions: direct temperature monitoring, abnormality detection through comparison, and thermal displacement compensation. The sensor essentially serves itself through sophisticated data processing
Data Source
AI summary
An abnormality determination apparatus, which determines abnormality of a temperature sensor in a machine tool, includes: a temperature pattern storage unit which stores a normal pattern indicating temperature change relative to machining time for a machining classification of the machine tool; a temperature data acquisition unit which acquires temperature data outputted by the temperature sensor provided to the machine tool; a machining classification determination unit which determines a machining classification of the machine tool; a comparison data acquisition unit which extracts the normal pattern relative to a determined machining classification from the temperature pattern storage unit; a comparison unit which compares the extracted normal pattern, and as acquired pattern indicating temperature change relative to machining time according to the acquired temperature data; and an abnormality determination unit which determines abnormality of a temperature sensor based on a comparison result.